Hyundai R290lc-7 Crawler Excavator Operating Manual by www.heydownloads.com

AUTOTOTAL MANUAL

Hyundai R290LC-7 Crawler Excavator Operating Manual

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

CONTENTS Foreword

0-1

6. Traveling of the machine

4-15

Before servicing this machine

0-2

7. Efficient working method

4-18

EC regulation approved

0-3

8. Operation in the special work sites

4-22

Table to enter S/No and distribution

0-4

9. Normal operation of excavator

4-24

Safety labels

0-5

10. Attachment lowering

4-25

Guide(Direction, S/No, Symbol)

0-14

11. Storage

4-26

12. RCV lever operating pattern

4-28

13. Switching hydraulic attachment circuit

4-29

SAFETY HINTS 1. Before operating the machine

1-1

2. During operating the machine

1-6

3. During maintenance

1-13

1. Preparation for transportation

5-1

4. Parking

1-16

2. Dimension and weight

5-2

3. Loading the machine

5-6

4. Fixing the machine

5-8

5. Loading and unloading by crane

5-9

SPECIFICATIONS

TRANSPOTATION

1. Major components

2-1

2. Specifications

2-2

3. Working range

2-8

4. Weight

2-9

1. Instruction

6-1

5. Lifting capacites

2-12

2. Tightening torque

6-6

6. Bucket selection guide

2-22

3. Fuel, coolant and lubricants

6-9

7. Undercarriage

2-24

4. Maintenance check list

6-11

8. Specification for major components

2-26

5. Maintenance chart

6-16

9. Recommended oils

2-30

6. Service instruction

6-18

7. Electrical system

6-39

8. Air conditioner and heater

6-42

CONTROL DEVICES

MAINTENANCE

1. Cab devices

3-1

2. Cluster

3-2

3. Switches

3-9

1. Engine

7-1

4. Levers and pedals

3-14

2. Electrical system

7-2

5. Air conditioner and heater

3-17

3. Others

7-3

6. Others

3-20

TROUBLESHOOTING GUIDE

HYDRAULIC BREAKER AND QUICK CLAMP OPERATION

1. Selecting hydraulic breaker

8-1

1. Suggestion for new machine

4-1

2. Circuit configuration

8-2

2. Check before starting the engine

4-2

3. Maintenance

8-3

3. Starting and stop the engine

4-3

4. Precaution while operating the breaker

8-4

4. Mode selection system

4-7

5. Quick clamp

8-6

5. Operation of the working device

4-14

INDEX

9-1

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

FOREWORD This manual contains a number of instructions and safety recommendations regarding driving, handling, lubrication, maintenance, inspection and adjustment of the excavator. The manual is to promote safety maintenance and enhance machine performance. Keep this manual handy and have all personnel read it periodically. If you sell the machine, be sure to give this manual to the new owners. This machine complies with EC directive "98/37/EEC". 1. Read and understand this manual before operating the machine. This operator's manual may contain attachments and optional equipment that are not available in your area. Please consult your local Hyundai distributor for those items you require. Improper operation and maintenance of this machine can be hazardous and could result in serious injury or death. Some actions involved in operation and maintenance of the machine can cause a serious accident, if they are not done in a manner described in this manual. The procedures and precautions given in this manual apply only to intended uses of the machine. If you use your machine for any unintended uses that are not specifically prohibited, you must be sure that it is safe for you and others. In no event should you or others engage in prohibited uses of actions as described in this manual. 2. Inspect the jobsite and follow the safety recommendations in the safety hints section before operating the machine. 3. Use genuine Hyundai spare parts for the replacement of parts. We expressly point out that Hyundai will not accept any responsibility for defects resulting from nongenuine parts or non workmanlike repair. In such cases Hyundai cannot assume liability for any damage. Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Hyundai or your Hyundai distributor for the latest available information for your machine or for questions regarding information in this manual.

0-1

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

BEFORE SERVICING THIS MACHINE It is the responsibility of the owner and all service and maintenance personnel to avoid accidents and serious injury by keeping this machine properly maintained. It also is the responsibility of the owner and all service and maintenance personnel to avoid accidents and serious injury while servicing the machine. No one should service or attempt to repair this machine without proper training and supervision. All service and maintenance personnel should be thoroughly familiar with the procedures and precautions contained in this manual. All personnel also must be aware of any federal, state, provincial or local laws or regulations covering the use and service of construction equipment. The procedures in this manual do not supersede any requirements imposed by federal, state, provincial or local laws. Hyundai can not anticipate every possible circumstance or environment in which this machine may be used and serviced. All personnel must remain alert to potential hazards. Work within your level of training and skill. Ask your supervisor if you are uncertain about a particular task. Do not try to do too much too fast. Use your common sense. TIER II : Machine with TIER II emission regulation certified engine.

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

EC REGULATION APPROVED · Noise level (EN474-1 ANNEX4.10 and 2000/14/EC) are as followings. LWA : 104dB(EU only) 104dB(EU only) : LOW NOISE LPA : 72dB

· The value of vibrations transmitted by the operator's seat are lower than standard value of (EN474-1 ANNEX 4.3.1.3)

0-3

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

Machine Serial No. Engine Serial No. Manufacturing year Manufacturer

Hyundai Heavy Industries co., Ltd.

Address

1 Chonha-Dong, Dong-Ku Ulsan The Republic of Korea.

Distributor for U.S.A

Hyundai Heavy Industries U.S.A, Inc

Address

955 Estes Avenue EIK Grove village IL, 60001 U.S.A

Distributor for Europe

Hyundai Heavy Industries Europe N. V.

Address

Vossendal 11 2240 Geel Belgium

Dealer Address

0-4

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

SAFETY LABELS 1. LOCATION Always keep these labels clean. If they are lost or damaged, attach them again or replace them with a new label. 17 39

34 9

9 34

16 15

3 32

33 13

35 36

29,30

19 22 23 42

26 21

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Air cleaner filter Turbo charger cover Radiator cap Fueling Battery corrosive Battery explosion Hydraulic oil level Hydraulic oil lub Keep clear Lifting eye Name plate Slinging ideogram Sidekeep clear Stay fix

29071FW04

15 16 17 18 19 20 21 22 23 24 25 26 27 28

Shearing engine hood No step engine hood Transporting Low emission engine Control ideogram Control ideogram(LH) Control ideogram(RH) Ref operator manual Max height Safety front window Safety rear window Air conditioner filter Console box tilting Safety lever

0-5

29 30 31 32 33 34 35 36 37 38 39 40 41 42

Model name(LH) Model name(RH) Logo(ROBEX) Trade mark(Boom) Trade mark(CWT) Keep clear work area Noise level LPA Noise level LWA Service instruction Lifting chart Step tread Interference Locking clamp Start procedure

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

2. DESCRIPTION There are several specific warning labels on this machine please become familiarized with all warning labels. Replace any safety label that is damaged, or missing. 1) AIR CLEANER FILTER(Item 1) This warning label is positioned on the air cleaner cover. Periodic and proper inspection, cleaning and change of elements prolong engine life time and maintain the good performance of engine. 21070FW01

2) TURBO CHARGER COVER(Item 2) This warning label is positioned on the turbo charger cover. Do not touch turbo charger or it may cause severe burn.

21070FW02

3) RADIATOR CAP(Item 3) This warning label is positioned on the radiator. Never open the filler cap while engine running or at high coolant temperature.

14070FW03

4) FUELING(Item 4) This warning label is positioned on the right side of fuel filler neck. Stop the engine when refueling. All lights or flames shall be kept at a safe distance while refueling.

STOP

21070FW04

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

5) BATTERY CORROSIVE(Item 5) This warning label is positioned on the battery cover. Electrolyte containing sulfuric acid cause severe burns. Avoid being in contact with skin, eyes or clothes. In the event of accident flush with sufficient water, call a physician immediately. Maintain the electrolyte at the recommended level. Add distilled water to the battery only when starting up, never when shutting down. With electrolyte at proper level, less space may cause the gases to be accmulated in the battery.

21070FW05

6) BATTERY EXPLOSION(Item 6) This warning label is positioned on the battery cover. Extinguish all smoking materials and open flames before checking the battery. Do not use matches, lighters or torches as a light source near the battery for the probable presence of explosive gas. Do not allow unauthorized personnel to change the battery or to use booster cables.

21070FW06

7) HYDRAULIC OIL LEVEL(Item 7) This warning label is positioned on the left side of hydraulic oil level. Place the bucket on the ground whenever servicing the hydraulic system. Check oil level on the level gauge. Refill the recommended hydraulic oil up to specified level if necessary.

STOP

21070FW07

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

8) HYDRAULIC OIL LUBRICATION(Item 8) This warning label is positioned on the right side of air breather. Do not mix with different brand oils. Never open the filler cap while engine running or at high coolant temperature. Loosen the cap slowly and release internal pressure completely. 14070FW08

9) KEEP CLEAR(Item 9) This warning label is positioned on the counterweight. To prevent serious personal injury or death keep clear or machine swing radius. Do not deface of remove this label from the machine.

21070FW28

10) LIFTING EYE(Item 10) This warning label is positioned on the counterweight. Do not lift the machine by using lifting eyes on the counterweight or the lifting eyes may be subject to overload causing its breaking and possible personal injury. See page 5-7 for proper lifting method of the machine. 21070FW10

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

11) SIDE KEEP CLEAR(Item 13) This warning label is positioned on the side of counterweight. To prevent serious personal injury or death keep clear of machine swing radius. Do not deface or remove this label from the machine.

21070FW13

12) STAY FIX(Item 14) This warning label is positioned on the side cover. Be sure to support the stay when the door needs to be opened. Be careful that the opened door may be closed by the external or natural force like strong wind.

21070FW14

13) SHEARING-ENGINE HOOD(Item 15) This warning label is positioned on the engine hood. Don't open the engine hood during the engine's running. Don't touch exhaust pipe or it may cause severe burn. 21070FW15

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

14) NO STEP-ENGINE HOOD(Item 16) This warning label is positioned on the engine hood. Don't step on the engine hood.

21070FW15

15) TRANSPORTING(Item 17) This warning label is positioned right side of upper frame. Study the operator's manual before transporting the machine, if provided and tie down arm and track to the carrier with lashing wire. See page 5-6 for details. 14070FW17

16) CONTROL IDEOGRAM(Item 19) This warning label is positioned in right window of the cab. Check the machine control pattern for conformance to pattern on this label. If not, change label to match pattern before operating machine. Failure to do so could result in injury or death. See page 4-13 for details.

21070FW19

17) CONTROL IDEOGRAM-LH(Item 20) This warning label is positioned on the LH console box. Check the machine control pattern for conformance to pattern on this label. If not, change label to match pattern before operating machine. Failure to do so could result in injury or death. See page 4-13 for details.

21070FW20

0-10

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

18) CONTROL IDEOGRAM-RH(Item 21) This warning label is positioned on the RH console box. Check the machine control pattern for conformance to pattern on this label. If not, change label to match pattern before operating machine. Failure to do so could result in injury or death. See page 4-13 for details.

21070FW21

19) REF OPERATOR MANUAL(Item 22) This warning label is positioned on the right side window of the cab. Study the operator's manual before starting and operating machine.

21070FW22

20) MAX HEIGHT(Item 23) This warning label is positioned on the right side window of the cab. Serious injury or death can result from contact with electric lines. An electric shock being received by merely coming into the vicinity of an electric lines, the minimum distance should be kept considering the supply voltage as page 1-7.

21070FW23

21) SAFETY FRONT WINDOW(Item 24) This warning label is positioned on the inside of front window. Be careful that the front window may be promptly closed.

21070FW24

0-11

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

22) ALTERNATE EXIT(Item 25) This warning label is positioned on the inside of rear window. The rear window serves us an alternate exit. To remove rear window, pull the ring and push out the glass.

21070FW24

23) AIR CONDITIONER FILTER(Item 26) This warning label is positioned on the air conditioner cover. Periodic and proper inspection, cleaning and change of filter prolong air conditioner life time and mainntain good performance. 21070FW26

24) CONSOLE BOX TILTING(Item 27) This warning label is positioned on the LH console box. Before you get off the machine be sure to tilt the LH console box.

21070FW27

25) SAFETY LEVER(Item 28) This warning label is positioned on the cover safety. Before you get off the machine be sure to place the safety lever LOCKED position.

21070FW28

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

26) KEEP CLEAR-WORK AREA(Item 34) This warning label is positioned counterweight. To prevent serious personal injury or death keep clear of machine swing radius. Do not deface or remove this label from the machine. 21070FW34

27) INTERFERENCE(Item 39) This warning label is positioned on the right side window of cab. Be careful to operate machine equipped with quick clamp or extensions. Bucket may hit cab or boom, boom cylinders when it reached vicinity of them. 14070FW62

28) CLAMP-LOCKING(Item 40) This warning label is positioned on the right side window of cab. Serious injury or death can result from dropping bucket. Operating the machine with quick clamp switch unlocked or without safety pin of moving hook can cause the bucket to drop off.

14070FW60

29) START PROCEDURE(Item 42) This warning label is positioned on the right side window of the cab.

Start Procedure 1. Start ignition on. 2. Wait up to 4 seconds for grid heater operation in summer. (45 seconds in winter) 3. Start cranking. (Tier 3 QSB is equipped with mechanical fuel lift pump.) 4. If engine still does not start, turn the Keyswitch to OFF position. 5. Loosen fuel supply line at the outlet of pre-filter. 6. Do hand-priming repeatedly until air bubbles comes out from fuel supply line completely. 7. Tighten fuel supply line to its origin position. 8. Recranking. 9. If the engine still would not start, please contact the nearest HYUNDAI or Cummins dealers. 7607A0FW05

0-13

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

GUIDE 1. DIRECTION Forward

The direction of this manual indicate forward, backward, right and left on the standard of operator when the travel motor is in the rear and machine is on the traveling direction. Left

Right

Travel motor Backward 29070FW00

2. SERIAL NUMBER Inform following when you order parts or the machine is out of order. 1) MACHINE SERIAL NUMBER The numbers are located below in right of the operator's cab.

Machine serial No.

2) ENGINE SERIAL NUMBER The numbers are located on the engine name plate.

21070SN02

Engine serial No.

29070FW03

3. SYMBOLS Important safety hint. It indicates matters which can cause the great loss on the machine or the surroundings. It indicates the useful information for operator.

0-14

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

SAFETY HINTS 1. BEFORE OPERATING THE MACHINE Think-safety first. In special situation, wear protective clothing including a safety helmet, safety shoes, gloves, safety glasses and ear protection as required by the job condition. Almost every accident are caused by disregarding the simple and fundamental safety hints. 13031SH01

Be sure to understand thoroughly all about the operator's manual before operating the machine. Proper care is your responsibility.

13031SH02

Fully understand the details and process of the construction before starting the work. If you find anything dangerous on the job, consult with the job supervisor for the preventive measures before operating the machine.

13031SH03

Do not operate

when tired, or after drinking

alcoholic beverages, or any type of drugs.

13031SH05

1-1

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

Check daily according to the operation manual. Repair the damaged parts and tighten the loosened bolts.

13031SH05

Check for leakage of engine oil, hydraulic oil, fuel and coolant. Keep machine clean, clean machine regularly.

13031SH06

Do not operate the machine if it requires repairs. Operate after complete repair.

13031SH07

Be prepared if a fire starts. Keep a fire extinguisher handy and emergency numbers for a fire department near your telephone.

13031SH08

1-2

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

PROTECTION AGAINST FALLING OR FLYING OBJECTS If there is any danger of falling or flying objects hitting the operator, install protective guards in place to protect the operator as required for each particular situation. Be sure to close the front window before commencing work. Make sure to keep all persons other than operator outside the range of falling or flying objects. In case you need top guard, front guard and FOPS(Falling object protective structure), please contact Hyundai distributor in Europe.

14071SH01

UNAUTHORIZED MODIFICATION Any modification made without authorization from Hyundai can create hazards. Before making a modification, consult your Hyundai distributor. Hyundai will not be responsible for any injury or damage caused by any unauthorized modification.

PREPARE FOR EMERGENCY Extinguisher

Only in case of emergency, use the installed hammer for breaking the windshield of the cab, and then exit carefully. Have a fire extinguisher and first aid kit ready for emergencies such as fires or accidents. Learn how to use the fire extinguisher. Be sure you know the phone numbers of persons you should contact in case of an emergency.

Hammer 29071SH02

1-3

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

ROTATING BEACON

Beacon

When you operate a machine on a road or beside a road, a rotating beacon is required to avoid any traffic accident. Please contact your Hyundai distributor to install it.

21071SH03

PRECAUTIONS FOR ATTACHMENTS When installing and using an optional attachment, read the instruction manual for the attachment and the information related to attachments in this manual. Do not use attachments that are not authorized by Hyundai or your Hyundai distributor. Use of unauthorized attachments could create a safety problem and adversely affect the proper operation and useful life of the machine. Any injuries, accidents, product failures resulting from the use of unauthorized attachments will not the responsibility of Hyundai.

SAFETY RULES Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. When working with another operator or a person on worksite traffic duty, be sure all personnel understand all hand signals that are to be used.

1-4

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

SAFETY FEATURES Be sure all guards and covers are in their proper position. Have guards and covers repaired if damaged. Use safety features such as safety lock and seat belts properly. Never remove any safety features. Always keep them in good operating condition. Improper use of safety features could result in serious bodily injury or death.

MACHINE CONTROL PATTERN Check machine control pattern for conformance to pattern on label in cab. If not, change label to match pattern before operating machine. Failure to do so could result in injury.

CALIFORNIA PROPOSITION 65 Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm. This product contains or emits chemicals known to the State of California to cause cancer or birth defects or other reproductive harm.

WASH HANDS AFTER HANDLING !

Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING

: Battery posts, terminals and related accessories contain lead and lead compounds,chemicals known to the State of California to cause cancer and reproductive harm. 13031SH55

Do not load the machine with the lifting eyes on the counterweight. The wrong loading method can result in serious bodily injury or death.

1-5

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

2. DURING OPERATING THE MACHINE Use the handle and footstep when getting on or off the machine. Do not jump on or off the machine.

13031SH09

Sound the horn to warn nearby personnel before operating the machine. Remove all the obstacles like frost on the window before operating the machine for the good visibility.

13031SH10

Operate carefully to make sure all personnel or obstacles are clear within the working range of the machine. Place safety guards if necessary.

13031SH11

When using the work equipment, pay attention to job site.

13031SH12

1-6

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

Provide proper ventilation when operating engine in a closed area to avoid the danger of exhaust gases.

13031SH13

Check the locations of underground gas pipes or water line and secure the safety before operation.

13031SH14

The operating near the electrical lines is very dangerous. Operate within safe working range permitted as below. Supply voltage

Min safe separation

6.6kV

3m(10ft)

33.0kV

4m(13ft)

66.0kV

5m(16ft)

154.0kV

8m(26ft)

275.0kV

10m(33ft)

13031SH15

If the machine touches the electric power lines, keep sitting on the operator's seat and make sure the personnel on the ground not to touch the machine until turning off the electric current. Jump off the machine do not contact the machine when you need to get off.

13031SH16

1-7

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

Watch out for obstacles. Be particularly careful to check the machine clearance during the swing.

13031SH17

When using the machine as breaker or working in a place where stones may fall down, cab roof guard and head guard should be provided for proper protection.

13031SH18

Avoid operating on a cliff or soft ground as there is danger of rolling over. Make to get off easily as keeping the track at a right angle and putting the travel motor into the backward position when working on a cliff or soft ground inevitably.

13031SH19

Operate for the lifting work considering the capacity of machine, weight and width of the load. Be careful not to lift exceeding the machine capacity as it can be the cause of machine damage and safety accident.

13031SH20

1-8

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

The operation on a slope is dangerous. Avoid operating the machine on a slope of over 10 degree.

13031SH21

Operate the machine after making ground flat when operation is required on a slope.

13031SH22

The swing on the slope can be danger of rolling over. Do not operate to swing the machine with the bucket loaded on a slope since the machine may lose its balance under such an instance.

13031SH23

Avoid parking and stopping on a slope. Lower the bucket to the ground and block the track when parking.

13031SH24

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

Avoid traveling in a cross direction on a slope as it can cause the danger of rolling over and sliding.

13031SH25

Traveling on a slope is dangerous. Be sure to operate slowly when traveling down a slope and maintain the bucket at a height of 20~30cm(1ft) above the ground so that it can be used as brake in an emergency.

20~30cm

13031SH26

Steering of the machine while traveling on a slope is dangerous. When an inevitable turning of direction is required, turn on the flat and solid ground.

13031SH27

The engine angularity limits are 35 degree. Do not operate by more than the engine limits in any case.

35ă&#x20AC;&#x201A;

13031SH28

1-10

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

Before traveling the machine, sound the horn to warn nearby personnel. Operate forward and backward correctly with confirming the location of the travel motor.

13031SH29

Slow down when traveling through obstacles or uneven ground.

13031SH30

When working on soft ground, place mats or wood boards on the ground to prevent the machine sinking.

13031SH31

When operating in water or when crossing shallow, check the bed soil condition and depth and flow speed of water, then proceed taking care that water is not above carrier roller.

13031SH32

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

MOUNTING AND DISMOUNTING Never jump on or off the machine. Never get on or off a moving machine. When mounting or dismounting, always face the machine and use the handrails, machine or track frame steps, and track shoes. Additional track frame step can be fitted for wider optional shoe. In this case please contact your Hyundai distributor. Do not hold any control levers when getting on or off the machine. Ensure safety by always maintaining at least three-point contact of hands and feet with the handrails, steps or track shoes. Always remove any oil or mud from the handrails, steps and track shoes. If they are damaged, repair them and tighten any loose bolts. If grasping the door handrail when mounting or dismounting or moving on the track, open and lock the door securely in the open position. Otherwise, the door may move suddenly, causing you to lose balance and fall. 29071FW06

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

3. DURING MAINTENANCE Stop the engine immediately when the trouble of the machine is found. Inspect immediately the cause of trouble such as vibration, overheating and trouble in the cluster then repair.

13031SH33

Park on a flat place and stop the engine for inspecting and repairing. Properly TAG machine is not operational. (Remove start key) Extreme care shall be taken during maintenance work. Parts may require additional safe guard.

ON THE INSPECTION

13031SH34

Do not remove the radiator cap from hot engine. Open the cap after the engine cools, below 50ă&#x20AC;&#x201A; C(112ă&#x20AC;&#x201A; F) to prevent personal injury from heated coolant spray or steam.

13031SH35

Do not work below the machine. Be sure to work with proper safety supports. Do not depend on the hydraulic cylinders to hold up the equipment and attachment.

13031SH36

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

There is the danger of fire in fuel and oil. Store in cool dry area, away from any open flames.

13031SH37

Do not touch exhaust pipe, or may cause severe burn.

13031SH38

Do not open the engine hood and covers during the engine is running.

13031SH39

Be careful of not hitting the edges when you service engine.

13031SH40

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

Be careful that the front window may be promptly closed. Be sure to support stay, when the side door needs to be opened. Be careful that the open side door may closed by the external or national force like strong wind.

13031SH41

The antislip protection should be replaced if they have become worn or have been printed over.

13031SH42

Be careful of not touching slip, fall down etc., when you work at the upper frame to service engine and/or other component.

13031SH43

HIGH PRESSURE GAS Contain high pressure gas. To avoid explosion and personal injury, do not expose to fire, do not weld, do not drill. Relieve pressure before discharging. 45071SH03

LIFT EYES CAN FAIL Lift eyes or tank can fail when lifting tank containing fluids resulting in possible personal injury. Drain tank of all fluids before lifting. 1-15

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

4. PARKING When leaving the machine after parking, lower the bucket to the ground completely and put the safety lever at parking position then remove the key. Lock the cab door.

13031SH44

Park the machine in the flat and safe place.

13031SH45

Hope you can work easily and safely observing safety rules. For safe operation, observe all safety rules.

13031SH46

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

SPECIFICATIONS 1. MAJOR COMPONENT

Fuel tank

Tool box

Hydraulic oil tank

Main pump

Engine Radiator

Tooth

Arm

Bucket

Turning joint

Arm cylinder Boom

Bucket cylinder

Connecting link

Side cutter

Swing motor

Boom cylinder

Idler

Main control valve

Cab

Precleaner

Carrier roller

Connecting rod

Track roller

Battery

Muffler

Sprocket

Track

Oil cooler

Counterweight

Travel motor

29072SP00

2-1

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

2. SPECIFICATIONS 1) R290LC-7 I(I')

N B(L)

29072SP01

Description

Unit

Specification

Operating weight

kg(lb)

29300(64600)

Bucket capacity(PCSA heaped), standard

m (yd )

1.27(1.66)

Overall length

10560(34' 8")

Overall width, with 600mm shoe

3200(10' 6")

Overall height

3290(10' 10")

Superstructure width

2980( 9' 9")

Overall height of cab

3010( 9' 11")

Ground clearance of counterweight

1190( 3' 11")

Engine cover height

3190(10' 6")

Minimum ground clearance

Rear-end distance

3200(10' 6")

Rear-end swing radius

3120(10' 3")

Distance between tumblers

4030(13' 3")

Undercarriage length

4940(16' 2")

Undercarriage width

3200(10' 6")

Track gauge

2600( 8' 6")

Track shoe width, standard

600(24")

Travel speed(Low/high)

mm(ft-in)

500( 1' 8")

km/hr(mph)

3.1/5.2(1.9/3.2)

Swing speed

rpm

Gradeability

Degree(%)

35(70)

Ground pressure(600mm shoe)

kgf/cm2(psi)

0.56(7.97)

2-2

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

2) R290NLC-7 I(I')

M N

B(L)

29072SP02

Description

Unit

Specification

Operating weight

kg(lb)

29100(64150)

Bucket capacity(PCSA heaped), standard

m (yd )

1.27(1.66)

Overall length

10560(34' 8")

Overall width, with 600mm shoe

2990( 9' 10")

Overall height

3290(10' 10")

Superstructure width

2980( 9' 9")

Overall height of cab

3010( 9' 11")

Ground clearance of counterweight

1190( 3' 11")

Engine cover height

3190(10' 6")

Minimum ground clearance

Rear-end distance

3200(10' 6")

Rear-end swing radius

3120(10' 3")

Distance between tumblers

4030(13' 3")

Undercarriage length

4940(16' 2")

Undercarriage width

2990( 9' 10")

Track gauge

2390( 7' 10")

Track shoe width, standard

Travel speed(Low/high)

mm(ft-in)

500( 1' 8")

600(24") km/hr(mph)

3.1/5.2(1.9/3.2)

Swing speed

rpm

Gradeability

Degree(%)

35(70)

Ground pressure(600mm shoe)

kgf/cm2(psi)

0.55(7.82)

2-3

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

3) R290LC-7 LONG REACH

I(I')

M N

B(L)

29072SP06

Description

Unit

Specification

Operating weight

kg(lb)

32690(72630)

Bucket capacity(PCSA heaped), standard

m3(yd3)

0.52(0.68)

Overall length

14550( 47' 9")

Overall width, with 800mm shoe

3400( 11' 2")

Overall height

3550( 11' 8")

Superstructure width

2980( 9' 9")

Overall height of cab

3010( 9' 11")

Ground clearance of counterweight

1190( 3' 11")

Engine cover height

3190( 10' 6")

Minimum ground clearance

Rear-end distance

3200( 10' 6")

Rear-end swing radius

3120( 10' 3")

Distance between tumblers

4030( 13' 3")

Undercarriage length

4940( 16' 2")

Undercarriage width

3400( 11' 2")

Track gauge

2600( 8' 6")

Track shoe width, standard

800( 31' 5")

Travel speed(Low/high)

mm(ft-in)

500( 1' 8")

km/hr(mph)

3.1/5.2(1.9/3.2)

Swing speed

rpm

Gradeability

Degree(%)

35(70)

Ground pressure(800mm shoe)

kgf/cm (psi)

0.44(6.26)

2-4

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

4) R290LC-7 HIGH WALKER I(I')

M N

B(L)

29072SP07

Description

Unit

Specification

Operating weight

kg(lb)

32140(70860)

Bucket capacity(PCSA heaped), standard

m3(yd3)

1.27(1.66)

Overall length

10430( 34' 3")

Overall width, with 600mm shoe

3470( 11' 5")

Overall height

3350( 11' 0")

Superstructure width

2980( 9' 9")

Overall height of cab

3380( 11' 1")

Ground clearance of counterweight

1500( 4' 11")

Engine cover height

3500(11' 6")

Minimum ground clearance

Rear-end distance

3200(10' 6")

Rear-end swing radius

3120(10' 3")

Distance between tumblers

4030(13' 3")

Undercarriage length

4950(16' 3")

Undercarriage width

3470( 11' 5")

Track gauge

2870( 9' 5")

Track shoe width, standard

600(23' 6")

Travel speed(Low/high)

mm(ft-in)

765( 2' 6")

km/hr(mph)

3.1/5.2(1.9/3.2)

Swing speed

rpm

Gradeability

Degree(%)

35(70)

Ground pressure(600mm shoe)

kgf/cm (psi)

0.62(8.82)

2-5

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

3. WORKING RANGE 1) R290LC-7, R290NLC-7 [6.25m(20' 6") BOOM] A A'

B B' C

8ft 29072SP04

2.10m(6' 11") Arm

Description

2.50m(8' 2") Arm

3.05m(10' 0") Arm 3.75m(12' 4") Arm

Max digging reach

10020mm (32'10") 10280mm (33' 7") 10820mm (35' 6") 11400mm (37' 5")

Max digging reach on ground

9820mm (32' 3") 10080mm (33' 1") 10620mm (34'10") 11220mm (36'10")

Max digging depth

6440mm (21' 1")

6840mm (22' 5")

7500mm (24' 7")

8090mm (26' 7")

Max digging depth (8ft level)

6240mm (20' 6")

6630mm (21' 9")

7300mm (23'11")

7920mm (25'12")

Max vertical wall digging depth

6000mm (19' 8")

5850mm (19' 2")

6410mm (21' 0")

7080mm (23' 3")

Max digging height

Max dumping height

6940mm (22' 9")

7030mm (23' 1")

7110mm (23' 4")

7310mm (23'12")

Min swing radius

4380mm (14' 4")

4260mm (13'12")

4230mm (13'11")

4140mm (13' 7")

169[184] kN

SAE 17200[18760] kgf

17200[18760] kgf

37920[41370] lbf

192[210] kN

19600[21380] kgf

43210[47140] lbf

170[185] kN

147[161] kN

124[135] kN

109[119] kN

SAE 17300[18870] kgf

15000[16360] kgf

12600[13750] kgf

11100[12110] kgf

38140[41610] lbf

33070[36080] lbf

27780[30310] lbf

24470[26690] lbf

178[194] kN

154[168] kN

129[140] kN

112[122] kN

18100[19750] kgf

15700[17130] kgf

13100[14290] kgf

11400[12440] kgf

39900[43530] lbf

34610[37760] lbf

28880[31510] lbf

25130[27410] lbf

Bucket digging force ISO

Arm crowd force ISO

10070mm (33' 0") 10110mm (33' 2") 10160mm (33' 4") 10360mm (33'12")

[ ] : Power boost

2-6

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

2) R290LC-7 LONG REACH [10.2m(33' 6") BOOM] A A'

B B'

8ft 29072SP08

Description

7850(25' 9") Arm

Max digging reach

18510(60' 9")

Max digging reach on ground

18400(60' 4")

Max digging depth

14820(48' 7")

Max digging depth (8ft level)

14690(48' 2")

Max vertical wall digging depth

12020(39' 5")

Max digging height

14500(47' 7")

Max dumping height

12190(39'12")

Min swing radius

6250(20' 6") 70 kN

SAE

7100 kgf 15650 lbf

Bucket digging force

80 kN ISO

8200 kgf 18080 lbf 43 kN

SAE

4420 kgf 9740 lbf

Arm crowd force

44 kN ISO

4500 kgf 9920 lbf

2-7

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

3) R290LC-7 HIGH WALKER [6.25m(20' 6") BOOM] A A'

B B' C

8ft Description

2.10m(6' 11") Arm

29072SP03

2.50m(8' 2") Arm

3.05m(10' 0") Arm 3.75m(12' 4") Arm

Max digging reach

10020mm (32'10") 10280mm (33' 7") 10790mm (35' 5") 11400mm (37' 5")

Max digging reach on ground

9750mm (32' 0") 10020mm (32'10") 10530mm (34' 7") 11160mm (36' 7")

Max digging depth

6140mm (20' 2")

6540mm (21' 5")

7090mm (23' 3")

7790mm (25' 7")

Max digging depth (8ft level)

5930mm (19' 5")

6330mm (20' 9")

6910mm (22' 8")

7630mm (25' 0")

Max vertical wall digging depth

5700mm (18' 8")

5560mm (18' 3")

6090mm (20' 0")

6790mm (22' 3")

Max digging height

Max dumping height

7240mm (23' 9")

7170mm (23' 6")

7400mm (24' 3")

7610mm (25' 0")

Min swing radius

4380mm (14' 4")

4260mm (14' 0")

4230mm (13'11")

4140mm (13' 7")

169[184] kN

SAE 17200[18760] kgf

17200[18760] kgf

37920[41370] lbf

192[210] kN

19600[21380] kgf

43210[47140] lbf

170[185] kN

147[161] kN

124[135] kN

109[119] kN

SAE 17300[18870] kgf

15000[16360] kgf

12600[13750] kgf

11100[12110] kgf

38140[41610] lbf

33070[36080] lbf

27780[30310] lbf

24470[26690] lbf

178[194] kN

154[168] kN

129[140] kN

112[122] kN

18100[19750] kgf

15700[17130] kgf

13100[14290] kgf

11400[12440] kgf

39900[43530] lbf

34610[37760] lbf

28880[31510] lbf

25130[27410] lbf

Bucket digging force ISO

Arm crowd force ISO

10370mm (34' 0") 10220mm (33' 6") 10440mm (34' 3") 10660mm (35' 0")

[ ] : Power boost

2-8

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

4. WEIGHT 1) R290LC-7, R290NLC-7 Item

R290LC-7

R290NLC-7

Upperstructure assembly

12610

27800

←

Main frame weld assembly

2361

5210

←

Engine assembly

590

1300

←

Engine assembly(TIER II)

423

930

←

Main pump assembly

155

340

←

Main control valve assembly

200

442

←

Swing motor assembly

311

687

←

Hydraulic oil tank assembly

227

500

←

Fuel tank assembly

209

460

←

Counterweight

5200

11460

←

Cab assembly

310

680

←

Lower chassis assembly

10740

23680

10600

23370

Track frame weld assembly

3765

8300

3625

7990

Swing bearing

410

910

←

Travel motor assembly

350

770

←

Turning joint

120

←

Track recoil spring and idler

457

1010

←

Idler

252

560

←

Carrier roller

←

Track roller

119

←

Track-chain assembly (600mm standard triple grouser shoe)

1860

4110

←

Front attachment assembly(6.25m boom, 3.05m arm,1.27m3 PCSA heaped bucket)

5450

12020

←

6.25m boom assembly

2200

4860

←

3.05m arm assembly

975

2150

←

1.27m3 PCSA heaped bucket

960

2120

←

Boom cylinder assembly

290

640

←

Arm cylinder assembly

375

826

←

Bucket cylinder assembly

250

551

←

Bucket control rod assembly

112

248

←

2-9

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

2) R290LC-7 LONG REACH R290LC-7 LONG REACH

Item

Upperstructure assembly

14410

31810

Main frame weld assembly

2361

5210

Engine assembly

590

1300

Engine assembly(TIER II)

423

930

Main pump assembly

155

340

Main control valve assembly

200

442

Swing motor assembly

311

687

Hydraulic oil tank assembly

227

500

Fuel tank assembly

209

460

Counterweight

7000

15450

Cab assembly

310

680

Lower chassis assembly

10900

24030

Track frame weld assembly

3765

8300

Swing bearing

410

910

Travel motor assembly

350

770

Turning joint

120

Track recoil spring and idler

457

1010

Idler

252

560

Carrier roller

Track roller

119

Track-chain assembly(800mm standard triple grouser shoe)

2020

4450

Front attachment assembly(10.2m boom, 7.85m arm, 0.51m3 PCSA heaped bucket)

5350

11790

10.2m boom assembly

3320

7320

7.85m arm assembly

1590

3510

0.51m3 PCSA heaped bucket

440

970

Boom cylinder assembly

290

640

Arm cylinder assembly

375

826

Bucket cylinder assembly

212

Bucket control rod assembly

112

248

2-10

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

3) R290LC-7 HIGH WALKER R290LC-7 HIGH WALKER

Item

Upperstructure assembly

12610

27800

Main frame weld assembly

2361

5210

Engine assembly

590

1300

Engine assembly(TIER II)

423

930

Main pump assembly

155

340

Main control valve assembly

200

442

Swing motor assembly

311

687

Hydraulic oil tank assembly

227

500

Fuel tank assembly

209

460

Counterweight

5200

11460

Cab assembly

310

680

Lower chassis assembly

12800

28220

Track frame weld assembly

5825

12840

Swing bearing

410

910

Travel motor assembly

350

770

Turning joint

120

Track recoil spring and idler

457

1010

Idler

252

560

Carrier roller

Track roller

119

Track-chain assembly(600mm standard triple grouser shoe)

1860

4110

Front attachment assembly(6.25m boom, 3.05m arm, 1.27m3 PCSA heaped bucket)

5450

12020

6.25m boom assembly

2200

4860

3.05m arm assembly

975

2150

1.27m3 PCSA heaped bucket

960

2120

Boom cylinder assembly

290

640

Arm cylinder assembly

375

826

Bucket cylinder assembly

250

551

Bucket control rod assembly

112

248

2-11

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

5. LIFTING CAPACITIES 1) R290LC-7 (1) 6.25m(20' 6") boom, 2.10m(6' 11") arm equipped with 1.27m3(PCSA heaped) bucket and 600mm (24") triple grouser shoe.

: Rating over-front

: Rating over-side or 360 degree

Load radius Load point height 7.5m (25ft) 6.0m (20ft) 4.5m (15ft) 3.0m (10ft) 1.5m (5ft) Ground Line -1.5m (-5ft) -3.0m (-10ft) -4.5m (-15ft)

Note

kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb

3.0m(10ft)

4.5m(15ft)

At max. reach

6.0m(20ft)

7.5m(25ft)

Capacity

Reach m(ft)

*13470 *29700 *17570 *38740 *14150 *31200

*8940 *19710 *11660 *25710 *13520 *29810 *14060 *31000 *13770 *30360 *12710 *28020 *10330 *22770

*8940 *19710 10180 22440 9490 20920 9290 20480 9310 20530 9480 20900 9880 21780

*5760 *12700 *6090 *13430 *7040 *15520 *8270 *18230 *9370 *20660 *10020 *22090 *10110 *22290 *9440 *20810

*5760 *12700 *6090 *13430 *7040 *15520 6600 14550 6210 13690 5980 13180 5920 13050 6020 13270

*5900 *13010 *6210 *13690 *6800 *14990 7330 16160 7180 15830 7150 15760

4950 10910 4820 10630 4610 10160 4400 9700 4270 9410 4240 9350

*5290 *11660 *5380 *11860 5270 11620 4990 11000 4980 10980 5260 11600 5970 13160 *6180 *13620

4580 10100 3670 8090 3200 7050 2990 6590 2970 6550 3140 6920 3590 7910 4610 10160

8.01 (26.3) 8.90 (29.2) 9.42 (30.9) 9.64 (31.6) 9.58 (31.4) 9.23 (30.3) 8.57 (28.1) 7.47 (24.5)

1. Lifting capacity are based on SAE J1097 and ISO 10567. 2. Lifting capacity of the ROBEX series does not exceed 75% of tipping load with the machine on firm, level ground or 87% of full hydraulic capacity. 3. The load point is a hook located on the back of the bucket. 4. *indicates load limited by hydraulic capacity.

2-12

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

(2) 6.25m(20' 6") boom, 2.50m(8' 2") arm equipped with 1.27m3(PCSA heaped) bucket and 600mm (24") triple grouser shoe. Load radius Load point height 7.5m (25ft) 6.0m (20ft) 4.5m (15ft) 3.0m (10ft) 1.5m (5ft) Ground Line -1.5m (-5ft) -3.0m (-10ft) -4.5m (-15ft)

kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb

1.5m(5ft)

3.0m(10ft)

4.5m(15ft)

At max. reach 6.0m(20ft)

7.5m(25ft)

Capacity

Reach m(ft)

*14370 *31680 *16270 *16270 *18700 *35870 *35870 *41230 *15620 *34440

*14370 *31680 *18700 *41230 *15620 *34440

*8180 *8180 *6610 *6610 18030 *18030 *14570 *14570 *10910 10440 *7890 6700 *24050 23020 *17390 14770 *13040 9630 *9080 6270 *28750 21230 *20020 13820 *13950 9310 9870 6000 *30750 20530 *21760 13230 *13930 9260 *10120 5900 *30710 20410 *22310 13010 *13110 9390 *9690 5950 *28900 20700 *21360 13120 *11170 9720 *24630 21430

*5470 *12060 *5880 *12960 *6530 *14400 *7190 *15850 7180 15830 7110 15670

5060 11160 4900 10800 4660 10270 4430 9770 4270 9410 4210 9280

*4880 *10760 *5020 *11070 5070 11180 4790 10560 4770 10520 5000 11020 5610 12370 *6310 *13910

4330 9550 3510 7740 3080 6790 2870 6330 2840 6260 2980 6570 3360 7410 4210 9280

8.34 (27.4) 9.19 (30.2) 9.69 (31.8) 9.90 (32.5) 9.84 (32.3) 9.51 (31.2) 8.87 (29.1) 7.82 (25.7)

(3) 6.25m(20' 6") boom, 3.05m(10' 0") arm equipped with 1.27m3(PCSA heaped) bucket and 600mm (24") triple grouser shoe. Load radius Load point height 7.5m (25ft) 6.0m (20ft) 4.5m (15ft) 3.0m (10ft) 1.5m (5ft) Ground Line -1.5m (-5ft) -3.0m (-10ft) -4.5m (-15ft)

kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb

1.5m(5ft)

3.0m(10ft)

4.5m(15ft)

At max. reach

6.0m(20ft)

7.5m(25ft)

9.0m(30ft)

Capacity

Reach m(ft)

*10390 *22910 *14060 *31000 *18380 *40520

*9910 *9910 *9820 *21850 *21850 *21650 *12250 *27010 *9590 *9590 *13580 *21140 *21140 *29940 *13470 *13470 *13920 *29700 *29700 *30690 *18180 *18180 *13440 *40080 *40080 *29630 *17190 *17190 *11970 *37900 *37900 *26390

*9820 *21650 9780 21560 9290 20480 9140 20150 9200 20280 9450 20830

*5960 *13140 *7280 *16050 *8590 *18940 *9550 *21050 *10000 *22050 9830 21670 *8750 *19290

2-13

*5960 *13140 6780 14950 6310 13910 5980 13180 5820 12830 5810 12810 5990 13210

*4910 *10820 *5390 *11880 *6090 *13430 *6830 *15060 7150 15760 7030 15500 7050 15540

*4910 *10820 4950 10910 4690 10340 4430 9770 4230 9330 4130 9110 4150 9150

*4140 *9130 *4900 *10800 *4310 *9500

3380 7450 3240 7140 3140 6920

*4460 3830 *9830 8440 *4600 3160 *10140 6970 4640 2790 10230 6150 4400 2610 9700 5750 4360 2560 9610 5640 4550 2670 10030 5890 5020 2970 11070 6550 *5980 3610 *13180 7960 *5960 5120 *13140 11290

8.94 (29.3) 9.74 (32.0) 10.20 (33.5) 10.40 (34.1) 10.35 (34.0) 10.04 (32.9) 9.44 (31.0) 8.48 (27.8) 6.97 (22.9)

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

(4) 6.25m(20' 6") boom, 3.75m(12' 4") arm equipped with 1.27m3(PCSA heaped) bucket and 600mm (24") triple grouser shoe. Load radius Load point height 7.5m (25ft) 6.0m (20ft) 4.5m (15ft) 3.0m (10ft) 1.5m (5ft) Ground Line -1.5m (-5ft) -3.0m (-10ft) -4.5m (-15ft)

kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb

1.5m(5ft)

3.0m(10ft)

4.5m(15ft)

At max. reach

6.0m(20ft)

7.5m(25ft)

9.0m(30ft)

Capacity

Reach m(ft)

*6470 *14260 *9310 *20530 *12290 *27090 *15740 *34700

*13490 *29740 *9980 *22000 *10300 *22710 *12760 *28130 *16240 *35800 *18940 *41760

*13490 *29740 *9980 *22000 *10300 *22710 *12760 *28130 *16240 *35800 18940 41760

*8320 *18340 *11050 *24360 *12890 *28420 *13720 *30250 *13690 *30180 *12770 *28150

*8320 *18340 10090 22240 9400 20720 9090 20040 9040 19930 9190 20260

*6410 *14130 *7850 *17310 *9020 *19890 *9730 *21450 *9880 *21780 *9310 *20530

2-14

*6410 *14130 6420 14150 6010 13250 5770 12720 5700 12570 5780 12740

*4160 *9170 *4710 *10380 *5470 *12060 *6300 *13890 *7030 *15500 6970 15370 6920 15260

*4160 *9170 *4710 *10380 4760 10490 4470 9850 4220 9300 4070 8970 4020 8360

*2370 *2370 *5220 *5220 *3720 3550 *8200 7830 *4740 3400 *10450 7500 *5440 3240 *11990 7140 5300 3100 11680 6830 5210 3020 11490 6660

*3930 *8660 *4090 *9020 4160 9170 3950 8710 3920 8640 4050 8930 4410 9720 5140 11330 *5780 *12740

3310 7300 2770 6110 2460 5420 2300 5070 2260 4980 2330 5140 2560 5640 3030 6680 4030 8880

9.67 (31.7) 10.40 (34.1) 10.83 (35.5) 11.02 (36.2) 10.97 (36.0) 10.68 (35.0) 10.12 (33.2) 9.25 (30.3) 7.92 (26.0)

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

2) R290NLC-7 (1) 6.25m(20' 6") boom, 2.10m(6' 11") arm equipped with 1.27m3(PCSA heaped) bucket and 600mm (24") triple grouser shoe.

: Rating over-front

: Rating over-side or 360 degree

Load radius Load point height 7.5m (25ft) 6.0m (20ft) 4.5m (15ft) 3.0m (10ft) 1.5m (5ft) Ground Line -1.5m (-5ft) -3.0m (-10ft) -4.5m (-15ft)

Note

kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb

3.0m(10ft)

4.5m(15ft)

At max. reach

6.0m(20ft)

7.5m(25ft)

Capacity

Reach m(ft)

*13470 *29700 *17570 *38740 *14150 *31200

*13470 *29700 *17290 *38120 *14150 *31200

*8940 *19710 *11660 *25710 *13520 *29810 *14060 *31000 *13770 *30360 *12710 *28020 *10330 *22770

*8940 *19710 9090 20040 8420 18560 8220 18120 8240 18170 8410 18540 8800 19400

*5760 *12700 *6090 *13430 *7040 *15520 *8270 *18230 *9370 *20660 *10020 *22090 *10110 *22290 *9440 *20810

*5760 *12700 *6090 *13430 6390 14090 5930 13070 5550 12240 5330 11750 5270 11620 5370 11840

*5900 *13010 *6210 *13690 *6800 *14990 7290 16070 7140 15740 7110 15670

4470 9850 4350 9590 4140 9130 3940 8690 3800 8380 3780 8330

*5290 *11660 *5380 *11860 5250 11570 4960 10930 4950 10910 5230 11530 5930 13070 *6180 *13620

4140 9130 3300 7280 2860 6310 2660 5860 2640 5820 2790 6150 3210 7080 4130 9110

8.01 (26.3) 8.90 (29.2) 9.42 (30.9) 9.64 (31.6) 9.58 (31.4) 9.23 (30.3) 8.57 (28.1) 7.47 (24.5)

2-15

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb

1.5m(5ft)

3.0m(10ft)

4.5m(15ft)

At max. reach 6.0m(20ft)

7.5m(25ft)

Capacity

Reach m(ft)

*14370 *31680 *16270 *16270 *18700 *35870 *35870 *41230 *15620 *34440

*14370 *31680 17040 37570 *15620 *34440

*8180 *8180 *6610 18030 *18030 *14570 *10910 9330 *7890 *24050 20570 *17390 *13040 8550 *9080 *28750 18850 *20020 *13950 8240 *9870 *30750 18170 *21760 *13930 8190 10090 *30710 18060 22240 *13110 8310 *9690 *28900 18320 *21360 *11170 8630 *24630 19030

6500 14330 6030 13290 5610 12370 5350 11790 5250 11570 5300 11680

*5470 *12060 *5880 *12960 *6530 *14400 *7190 *15850 7140 15740 7070 15590

4580 10100 4420 9740 4190 9240 3970 8750 3810 8400 3740 8250

*4880 *10760 *5020 *11070 5040 11110 4760 10490 4740 10450 4970 10960 5580 12300 *6310 *13910

3920 8640 3160 6970 2750 6060 2550 5620 2520 5560 2640 5820 2990 6590 3770 8310

8.34 (27.4) 9.19 (30.2) 9.69 (31.8) 9.90 (32.5) 9.84 (32.3) 9.51 (31.2) 8.87 (29.1) 7.82 (25.7)

kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb

1.5m(5ft)

3.0m(10ft)

4.5m(15ft)

At max. reach

6.0m(20ft)

7.5m(25ft)

9.0m(30ft)

Capacity

Reach m(ft)

*10390 *22910 *14060 *31000 *18380 *40520

*9910 *9910 *9820 *21850 *21850 *21650 *12250 *27010 *9590 *9590 *13580 *21140 *21140 *29940 *13470 *13470 *13920 *29700 *29700 *30690 *18180 16660 *13440 *40080 36730 *29630 *17190 17140 *11970 *37900 37790 *26390

9600 21160 8690 19160 8220 18120 8080 17810 8130 17920 8370 18450

*5960 *13140 *7280 *16050 *8590 *18940 *9550 *21050 *10000 *22050 *9830 *21670 *8750 *19290

2-16

*5960 *13140 6110 13470 5650 12460 5320 11730 5170 11400 5160 11380 5330 11750

*4910 4670 *10820 10300 *5390 4480 *11880 9880 *6090 4220 *4140 *13430 9300 *9130 *6830 3960 *4900 *15060 8730 *10800 7110 3770 *4310 15670 8310 *9500 6990 3660 15410 8070 7010 3680 15450 8110

3010 6640 2880 6320 2780 6130

*4460 3460 *9830 7630 *4600 2830 *10140 6240 4610 2480 10160 5470 4370 2310 9630 5090 4340 2270 9570 5000 4520 2360 9960 5200 4990 2630 11000 5800 *5980 3220 *13180 7100 *5960 4600 *13140 10140

8.94 (29.3) 9.74 (32.0) 10.20 (33.5) 10.40 (34.1) 10.35 (34.0) 10.04 (32.9) 9.44 (31.0) 8.48 (27.8) 6.97 (22.9)

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

6.25m(20' 6") boom, 3.75m(12' 4") arm equipped with 1.27m3(PCSA heaped) bucket and 600mm (24") triple grouser shoe. Load radius Load point height 7.5m (25ft) 6.0m (20ft) 4.5m (15ft) 3.0m (10ft) 1.5m (5ft) Ground Line -1.5m (-5ft) -3.0m (-10ft) -4.5m (-15ft)

kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb

1.5m(5ft)

3.0m(10ft)

4.5m(15ft)

At max. reach

6.0m(20ft)

7.5m(25ft)

9.0m(30ft)

Capacity

Reach m(ft)

*6470 *14260 *9310 *20530 *12290 *27090 *15740 *34700

*13490 *29740 *9980 *22000 *10300 *22710 *12760 *28130 *16240 *35800 *18940 *41760

*13490 *29740 *9980 *22000 *10300 *22710 *12760 *28130 *16240 *35800 16670 36750

*8320 *18340 *11050 *24360 *12890 *28420 *13720 *30250 *13690 *30180 *12770 *28150

*8320 *18340 8990 19820 8320 18340 8020 17680 7970 17570 8120 17900

*6410 *14130 *7850 *17310 *9020 *19890 *9730 *21450 *9880 *21780 *9310 *20530

2-17

6280 13850 5760 12700 5360 11820 5120 11290 5050 11130 5120 11290

*4160 *4160 *2370 *2370 *9170 *9170 *5220 *5220 *4710 4560 *3720 3180 *10380 10050 *8200 7010 *5470 4280 *4740 3030 *12060 9440 *10450 6680 *6300 3990 5420 2870 *13890 8800 11950 6330 *7030 3750 5270 2740 *15500 8270 11620 6040 6930 3600 5180 2660 15280 7940 11420 5860 6880 3550 15170 7830

*3930 *8660 *4090 *9020 4140 9130 3930 8660 3890 8580 4030 8880 4380 9660 5110 11270 *5780 *12740

2980 6570 2470 5450 2180 4810 2020 4450 1980 4370 2040 4500 2250 4960 2680 5910 3590 7910

9.67 (31.7) 10.40 (34.1) 10.83 (35.5) 11.02 (36.2) 10.97 (36.0) 10.68 (35.0) 10.12 (33.2) 9.25 (30.3) 7.92 (26.0)

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

3) R290LC-7 LONG REACH (1) 10.2m(33' 6") boom, 7.85m(25' 9") arm equipped with 0.52m3(PCSA heaped) bucket and 800mm (32") triple grouser shoe.

Load point height

: Rating over-front

: Rating over-side or 360 degree

Load radius 3.0m(10.0ft)

6.0m(20.0ft)

9.0m(30.0ft)

At max. reach 12.0m(40.0ft) 15.0m(50.0ft)

Capacity

m(ft) 12.0m (40.0ft) 9.0m (30.0ft) 6.0m (20.0ft) 3.0m (10.0ft) Ground Line -3.0m (-10.0ft) -6.0m (-20.0ft) -9.0m (-30.0ft) -12.0m (-40.0ft)

Note

Reach m(ft)

kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb

*3780 *8330 *5080 *11200 *6810 *15010 *8960 *19750 *11900 *26230

*6710 *6710 *14790 *14790 *7970 5900 *17570 13010 *8310 5710 *18320 12590 *7890 5920 *17390 13050 *6420 *6420 *14150 *14150

*3000 *6610 *4000 *8820 *4770 *10520 *5150 *11350 *5050 *11130 *4120 *9080

*3000 *6610 3900 8600 3370 7430 3160 6970 3210 7080 3560 7850

*2390 *5270 *2920 *6440 *3370 *7430 *3630 *8000 *3520 *7760

*2390 *5270 2480 5470 2190 4830 2050 4520 2100 4630

*1420 *3130 *1830 *4030 *2080 *4590 *2380 *5250 *2630 *5800 *2550 *5620

*1420 *3130 *1830 *4030 1830 4030 1630 3590 1480 3260 1430 3150

*1630 *3590 *1690 *3730 *1790 *3950 *1920 *4230 2070 4560 2170 4780 2470 5450 *2800 *6170

*1630 *3590 1600 3530 1310 2890 1150 2540 1100 2430 1140 2510 1330 2930 1800 3970

15.27 (50.1) 16.89 (55.4) 17.83 (58.5) 18.20 (59.7) 18.04 (59.2) 17.33 (56.9) 15.99 (52.5) 13.83 (45.4)

2-18

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

4) R290LC-7 HIGH WALKER (1) 6.25m(20' 6") boom, 2.10m(6' 11") arm equipped with 1.27m3(PCSA heaped) bucket and 600mm (24") triple grouser shoe.

: Rating over-front

: Rating over-side or 360 degree

Load radius Load point height 7.5m (25ft) 6.0m (20ft) 4.5m (15ft) 3.0m (10ft) 1.5m (5ft) Ground Line -1.5m (-5ft) -3.0m (-10ft) -4.5m (-15ft)

Note

kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb

3.0m(10ft)

4.5m(15ft)

At max. reach

6.0m(20ft)

7.5m(25ft)

Capacity

Reach m(ft)

*14990 *33050 *17110 *37720 *13230 *29170

*9430 *20790 *12110 *26700 *13700 *30200 *14060 *31000 *13640 *30070 *12400 *27340 *9610 *21190

*9430 *20790 12050 26570 11450 25240 11290 24890 11340 25000 11560 25490 *9610 *21190

*5750 *12680 *6220 *13710 *7260 *16010 *8490 *18720 *9530 *21010 *10080 *22220 *10050 *22160 *9200 *20280

*5750 *12680 *6220 *13710 *7260 *16010 7800 17200 7430 16380 7230 15940 7200 15870 7340 16180

*5920 *13050 *6310 *13910 *6910 *15230 *7490 *16510 *7830 *17260 *7690 *16950

5880 12960 5720 12610 5500 12130 5300 11680 5180 11420 5180 11420

*5300 *11680 *5400 *11900 *5560 *12260 5540 12210 5590 12320 5970 13160 *6270 *13820 *6100 *13450

5190 11440 4290 9460 3840 8470 3640 8020 3660 8070 3910 8620 4520 9960 5900 13010

8.21 (26.9) 9.02 (29.6) 9.48 (31.1) 9.65 (31.7) 9.54 (31.3) 9.14 (30.0) 8.40 (27.6) 7.21 (23.7)

2-19

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

(2) 6.25m(20' 6") boom, 2.50m(8' 2") arm equipped with 1.27m3(SAE heaped) bucket and 600mm (24") triple grouser shoe. Load radius Load point height 7.5m (25ft) 6.0m (20ft) 4.5m (15ft) 3.0m (10ft) 1.5m (5ft) Ground Line -1.5m (-5ft) -3.0m (-10ft) -4.5m (-15ft)

kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb

1.5m(5ft)

3.0m(10ft)

4.5m(15ft)

At max. reach 6.0m(20ft)

7.5m(25ft)

Capacity

Reach m(ft)

*12300 *27120 *17240 *38010

*9530 *21010 *15460 *34080 *18270 *40280 *14820 *32670

*8660 *19090 *11380 *25090 *13300 *29320 *14010 *30890 *13840 *30510 *12870 *28370 *10610 *23390

*8660 *19090 *11380 *25090 11560 25490 11290 24890 11280 24870 11450 25240 *10610 *23390

*5770 *5770 *5520 *5520 *12720 *12720 *12170 *12170 *6830 *6830 *5990 5790 *15060 *15060 *13210 12760 *8130 7900 *6650 5550 *17920 17420 *14660 12240 *9260 7490 *7300 5330 *20410 16510 *16090 11750 *9960 7240 *7730 5180 *21960 15960 *17040 11420 *10100 7170 *7780 5140 *22270 15810 *17150 11330 *9510 7250 *20970 15980

*4910 *4910 *10820 *10820 *5060 4120 *11160 9080 *5240 3690 *11550 8140 5330 3500 11750 7720 5350 3500 11790 7720 5680 3710 12520 8180 *6210 4230 *13690 9330 *6300 5380 *13890 11860

8.52 (28.0) 9.30 (30.5) 9.75 (32.0) 9.91 (32.5) 9.80 (32.2) 9.42 (30.9) 8.71 (28.6) 7.58 (24.9)

(3) 6.25m(20' 6") boom, 3.05m(10' 0") arm equipped with 1.27m3(SAE heaped) bucket and 600mm (24") triple grouser shoe. Load radius Load point height 7.5m (25ft) 6.0m (20ft) 4.5m (15ft) 3.0m (10ft) 1.5m (5ft) Ground Line -1.5m (-5ft) -3.0m (-10ft) -4.5m (-15ft)

kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb

1.5m(5ft)

3.0m(10ft)

4.5m(15ft)

At max. reach

6.0m(20ft)

7.5m(25ft)

9.0m(30ft)

Capacity

Reach m(ft)

*11020 *24290 *14780 *32580 *19280 *42510

*6850 *15100 *10250 *22600 *14240 *31390 *19180 *42280 *16520 *36420

*10320 *22750 *12580 *27730 *13710 *30230 *13900 *30640 *13260 *29230 *11550 *25460

*10320 *22750 11680 25750 11260 24820 11150 24580 11240 24780 11540 25440

*6180 *13620 *7530 *16600 *8790 *19380 *9670 *21320 *10020 *22090 *9720 *21430 *8370 *18450

2-20

*6180 *13620 *7530 *16600 7520 16580 7210 15900 7080 15610 7100 15650 7320 16140

*3300 *7280 *4980 *10980 *5510 *12150 *6230 *13730 *6950 *15320 *7500 *16530 *7720 *17020 *7360 *16230

*3300 *7280 *4980 *10980 *5510 *12150 5580 12300 5320 11730 5140 11330 5050 11130 5100 11240

*2910 *2910 *6420 *6420 *4340 4080 *9570 8990 *4920 3950 *10850 8710

*4480 4400 *9880 9700 *4630 3730 *10210 8220 *4820 3370 *10630 7430 4900 3200 10800 7050 4910 3190 10820 7030 5160 3350 11380 7390 5760 3760 12700 8290 *6010 4610 *13250 10160

9.12 (29.9) 9.84 (32.3) 10.26 (33.7) 10.41 (34.2) 10.31 (33.8) 9.95 (32.6) 9.29 (30.5) 8.25 (27.1)

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb

1.5m(5ft)

3.0m(10ft)

4.5m(15ft)

At max. reach

6.0m(20ft)

7.5m(25ft)

9.0m(30ft)

Capacity

Reach m(ft)

*6990 *15410 *9830 *21670 *12870 *28370 *16450 *36270

*14870 *32780 *9690 *21360 *10660 *23500 *13320 *29370 *16990 *37460 *18430 *40630

*8850 *19510 *11460 *25260 *13120 *28920 *13780 *30380 *13590 *29960 *12480 *27510

*8850 *19510 *11460 *25260 11340 25000 11080 24430 11060 24380 11250 24800

*6680 *14730 *8090 *17840 *9190 *20260 *9800 *21610 *9840 *21690 *9100 *20060

2-21

*6680 *14730 7620 16800 7230 15940 7020 15480 6970 15370 7080 15610

*4240 *9350 *4830 *10650 *5620 *12390 *6450 *14220 *7130 *15720 *7550 *16640 *7530 *16600

*4240 *9350 4830 10650 *5620 *12390 5350 11790 5120 11290 4980 10980 4950 10910

*2680 *5910 *3910 *8620 *4930 *10870 *5530 *12190 5910 13030 *4790 *10560

*2680 *5910 *3910 *8620 4100 9040 3940 8690 3810 8400 3740 8250

*3960 3850 *8730 8490 *4120 3310 *9080 7300 *4310 3000 *9500 6610 4420 2850 9740 6280 4420 2830 9740 6240 4610 2950 10160 6500 5060 3260 11160 7190 *5610 3880 *12370 8550 *5790 5250 *12760 11570

9.83 (32.3) 10.50 (34.4) 10.89 (35.7) 11.03 (36.2) 10.93 (35.9) 10.60 (34.8) 9.99 (32.8) 9.04 (29.7) 7.61 (25.0)

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

6. BUCKET SELECTION GUIDE 1) GENERAL BUCKET

0.79m3 SAE heaped bucket

※1.27m3 SAE heaped bucket

1.03m3 SAE heaped bucket

Capacity

1.50m3 SAE heaped bucket

Width Weight

SAE heaped

CECE heaped

Without side cutter

With side cutter

0.79m3 (1.03yd3)

0.70m3 (0.92yd3)

890mm (35.0")

1010mm (39.8")

790kg (1740lb)

1.03m3 (1.35yd3)

0.90m3 (1.18yd3)

1090mm (42.9")

1210mm (47.6")

890kg (1960lb)

※1.27m3 (1.66yd3)

1.10m3 (1.44yd3)

1290mm (50.8")

1410mm (55.5")

1010kg (2230lb)

1.50m3 (1.96yd3)

1.30m3 (1.70yd3)

1490mm (58.7")

1610mm (63.4")

1080kg (2380lb)

1.73m3 (2.26yd3)

1.50m3 (1.96yd3)

1700mm (66.9")

1820mm (71.7")

1170kg (2580lb)

1.85m3 (2.42yd3)

1.60m3 (2.09yd3)

1800mm (70.9")

1920mm (75.6")

1230kg (2710lb)

1.73m3 SAE heaped bucket

Recommendation 6.25m (20' 6") boom 2.1m arm 2.5m arm 3.05m arm 3.75m arm (6' 11") (8' 2") (10' 0") (12' 4")

※ : Standard bucket

Applicable for materials with density of 2000kgf/m3 (3370lbf/yd3) or less Applicable for materials with density of 1600kgf/m3 (2700lbf/yd3) or less Applicable for materials with density of 1100kgf/m3 (1850lbf/yd3) or less

2-22

1.85m3 SAE heaped bucket

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

2) ROCK AND HEAVY DUTY BUCKET

ľ1.07m3 SAE ľ1.15m3 SAE heaped bucket

Capacity

ľ1.27m3 SAE heaped bucket

Ľ1.16m3 SAE Ľ1.49m3 SAE heaped bucket

ľ1.46m3 SAE heaped bucket

Width Weight

SAE heaped

CECE heaped

Without side cutter

With side cutter

ľ1.07m3 (1.40yd3)

0.95m3 (1.24yd3)

1150mm (45.3")

1120kg (2470lb)

ľ1.15m3 (1.50yd3)

1.00m3 (1.31yd3)

1210mm (47.6")

1160kg (2560lb)

ľ1.27m3 (1.66yd3)

1.10m3 (1.44yd3)

1310mm (51.6")

1210kg (2670lb)

ľ1.46m3 (1.91yd3)

1.28m3 (1.67yd3)

1460mm (57.5")

1290kg (2840lb)

1.16m3 (1.52yd3)

1.00m3 (1.31yd3)

1340mm (52.8")

1280kg (2820lb)

1.49m (1.95yd3)

1.28m (1.67yd3)

1620mm (63.8")

1440kg (3170lb)

Recommendation 6.25m (20' 6") boom 2.1m arm 2.5m arm 3.05m arm 3.75m arm (6' 11") (8' 2") (10' 0") (12' 4")

ľ : Heavy duty bucket : Rock bucket

2-23

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

7. UNDERCARRIAGE 1) TRACKS X-leg type center frame is integrally welded with reinforced box-section track frames. The design includes dry tracks, lubricated rollers, idlers, sprockets, hydraulic track adjusters with shock absorbing springs and assembled track-type tractor shoes with triple grousers. 2) TYPES OF SHOES Triple grouser Model

R290LC-7

Shapes

Shoe width

mm(in)

600(24)

700(28)

800(32)

900(36)

Operating weight

kg(lb)

29300(64600)

29880(65870)

30460(67150)

31040(68430)

0.56(7.97)

0.49(6.97)

0.44(6.26)

0.38(5.40)

mm(ft-in)

3200(10' 6")

3300(10' 10")

3400(11' 1")

3500(11' 5")

Shoe width

mm(in)

600(24)

Operating weight

kg(lb)

29100(64150)

0.55(7.82)

mm(ft-in)

2990( 9'10")

Shoe width

mm(in)

800(32)

Operating weight

kg(lb)

31890(70310)

Ground pressure kgf/cm2(psi)

0.44(6.26)

Overall width

mm(ft-in)

3400(11' 2")

Shoe width

mm(in)

600(24)

700(28)

800(32)

Double Grouser

Operating weight

kg(lb)

32140(70860)

32720(72140)

33300(73410)

33310(73440)

0.62(8.82)

0.54(7.68)

0.48(6.83)

0.54(7.68)

3470(11' 5")

3570(11' 9")

3670(12' 0")

3580(11' 9")

Ground pressure kgf/cm2(psi) Overall width

R290NLC-7

Ground pressure kgf/cm2(psi) Overall width R290LC-7 LONG REACH

R290LC-7 HIGH WALKER

Ground pressure kgf/cm2(psi) Overall width

mm(ft-in)

3) NUMBER OF ROLLERS AND SHOES ON EACH SIDE Item

Quantity

Carrier rollers

2EA

Track rollers

9EA

Track shoes

48EA

2-24

710(28)

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

4) SELECTION OF TRACK SHOE Suitable track shoes should be selected according to operating conditions. Method of selecting shoes Confirm the category from the list of applications in table 2, then use table 1 to select the shoe. Wide shoes(Categories B and C) have limitations on applications. Before using wide shoes, check the precautions, then investigate and study the operating conditions to confirm if these shoes are suitable. Select the narrowest shoe possible to meet the required flotation and ground pressure. Application of wider shoes than recommendations will cause unexpected problem such as bending of shoes, crack of link, breakage of pin, loosening of shoe bolts and the other various problems.

※ Table 1 Specification

Category

600mm triple grouser

Standard

700mm triple grouser

Option

710mm double grouser

Option

800mm triple grouser

Option

900mm triple grouser

Option

Standard

Track shoe

800mm triple grouser(Long reach)

※ Table 2 Category A

Applications

Precautions

Rocky ground, river beds, normal soil

· Travel at low speed on rough ground with large obstacles such as

Normal soil, soft ground

· These shoes cannot be used on rough ground with large obstacles such

boulders or fallen trees

as boulders or fallen trees · Travel at high speed only on flat ground · Travel slowly at low speed if it is impossible to avoid going over obstacles

Extremely soft gound · Use the shoes only in the conditions that the machine sinks and it is (Swampy ground) impossible to use the shoes of category A or B · These shoes cannot be used on rough ground with large obstacles such as boulders or fallen trees · Travel at high speed only on flat ground · Travel slowly at low speed if it is impossible to avoid going over obstacles

2-25

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

8. SPECIFICATIONS FOR MAJOR COMPONENTS 1) ENGINE Specification

Item Model

Cummins C8.3-C

Type

4-cycle turbocharged diesel engine

Cooling method

Water cooling

Number of cylinders and arrangement

6 cylinders, in-line

Firing order

1-5-3-6-2-4

Combustion chamber type

Direct injection type

Cylinder bore×stroke

114×135mm(4.49"×5.32")

*102×112(4.02"×4.72")

Piston displacement

8270cc(505cu in)

*5900cc(360cu in)

Compression ratio

17.3 : 1

*16.3

Rated gross horse power(SAE J1995)

*Cummins QSB 5.9-C

195Hp at 1900rpm(145kW at 1900rpm) *213Hp at 1900rpm(159kW at 1900rpm) 62.1kgf·m(449lbf·ft) at 1600rpm

Maximum torque

*94.7kgf·m(685lbf·ft) at 1500rpm Engine oil quantity

18.9ℓ(4.9U.S. gal)

*23.7ℓ(6.3U.S. gal)

Dry weight

588kg(1296lb)

*489kg(1012lb)

High idling speed

2093+50rpm

*1950+50rpm

Low idling speed

800±100rpm

*700±50rpm

Rated fuel consumption

166.3g/Hp·hr at 1900rpm

*154.4g/Hp·hr at 1900rpm

Starting motor

Nippon denso(24V-7.5kW)

*(24V-4.5kW)

Alternator

Delco Remy 24V-50A

Battery

2×12V×160Ah

* : TIER II

2) MAIN PUMP Item

Specification

Type

Variable displacement tandem axis piston pumps

Capacity

2×136.8cc/rev

Maximum pressure

330kgf/cm2 (4690psi)[360kgf/cm2 (5120psi)]

Rated oil flow

2×260ℓ/min (68.7U.S. gpm/ 57.2U.K. gpm)

Rated speed

1900rpm

[ ]: Power boost

2-26

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

3) GEAR PUMP Item

Specification

Type

Fixed displacement gear pump single stage

Capacity

15cc/rev

Maximum pressure

35kgf/cm2(500psi)

Rated oil flow

28.5˶/min(7.5U.S. gpm/6.3U.K. gpm)

4) MAIN CONTROL VALVE Item

Specification

Type

9 spools

Operating method

Hydraulic pilot system

Main relief valve pressure

330kgf/cm2(4690psi)[360kgf/cm2(5120psi)]

Overload relief valve pressure

390kgf/cm2(5550psi)

[ ]: Power boost

5) SWING MOTOR Item

Specification

Type

Two fixed displacement axial piston motor

Capacity

169.4cc/rev

Relief pressure

265kgf/cm2(3770psi)

Braking system

Automatic, spring applied hydraulic released

Braking torque

70kgfÂm(506lbfÂft)

Brake release pressure

28.5~32kgf/cm2(405~455psi)

Reduction gear type

2 - stage planetary

Swing speed

11rpm

6) TRAVEL MOTOR Item

Specification

Type

Variable displacement axial piston motor

Relief pressure

330kgf/cm2(4620psi)

Capacity(max / min)

279.1/160cc/rev

Reduction gear type

2-stage planetary

Braking system

Automatic, spring applied hydraulic released

Brake release pressure

Braking torque

15.7kgf/cm2(223psi, ~#1214) 9kgf/cm2(128psi, #1215~) 78.8kgfÂm(570lbfÂft, ~#1214) 40kgf/cm2(289psi, #1215~)

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

7) REMOTE CONTROL VALVE Item

Specification

Type

Pressure reducing type

Operating pressure Single operation stroke

Minimum

6.5kgf/cm2(92psi)

Maximum

26kgf/cm2(370psi)

Lever

61mm(2.4in)

Pedal

123mm(4.84in)

8) CYLINDER Specification

Item Boom cylinder

Bore dia×Rod dia×Stroke Ø140×Ø100×1465mm Cushion

Extend only

Bore dia×Rod dia×Stroke Ø150×Ø110×1765mm

Arm cylinder

Cushion Bucket cylinder Bucket cylinder (LONG REACH)

Extend and retract

Bore dia×Rod dia×Stroke Ø140×Ø95×1185mm Cushion

Extend only

Bore dia ×Rod dia×Stoke

Ø100×Ø70×Ø870

Cushion

Extend only

※ Discoloration of cylinder rod can occur when the friction reduction additive of lubrication oil spreads on the rod surface. ※ Discoloration does not cause any harmful effect on the cylinder performance.

9) SHOE Item Standard R290LC-7

Option

Width

Ground pressure

Link quantity

Overall width

600mm(24")

0.56kgf/cm2(7.97psi)

3200mm(10' 6")

700mm(28")

0.49kgf/cm2(6.97psi)

3300mm(10' 10")

800mm(32")

0.44kgf/cm2(6.26psi)

3400mm(11' 1")

900mm(36")

0.38kgf/cm2(5.40psi)

3500mm(11' 5")

R290NLC-7

Standard

600mm(24")

0.55kgf/cm2(7.82psi)

2990mm( 9' 10")

R290LC-7

Standard

800mm(32")

0.44kgf/cm2(6.26psi)

3400mm(11' 2")

Standard

600mm(24")

0.62kgf/cm2(8.82psi)

3470mm(11' 5")

700mm(28")

0.54kgf/cm (7.68psi)

3570mm(11' 9")

800mm(32")

0.48kgf/cm2(6.83psi)

3670mm(12' 0")

*710mm(28")

0.54kgf/cm (7.68psi)

3580mm(11' 9")

LONG REACH

R290LC-7 HIGH WALKER

Option

※ : Double grouser.

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

10) BUCKET Capacity

Item Standard

R290LC-7 R290NLC-7 H/WALKER

Option

Width Tooth quantity Without side cutter With side cutter

PCSA heaped

CECE heaped

1.27m3(1.66yd3)

1.10m3(1.44yd3)

1290mm(50.8")

1410mm(55.5")

0.79m3(1.03yd3)

0.70m3(0.92yd3)

890mm(35.0")

1010mm(39.8")

1.03m3(1.35yd3)

0.90m3(1.18yd3)

1090mm(42.9")

1210mm(47.6")

◈1.07m3(1.40yd3)

0.95m3(1.24yd3)

1060mm(42.0")

◈1.27m3(1.66yd3)

1.10m3(1.44yd3)

1220mm(48.0")

◈1.46m3(1.91yd3)

1.28m3(1.67yd3)

1370mm(54.0")

1.16m3(1.52yd3)

1.00m3(1.05yd3)

1305mm(51.4")

1.50m3(1.96yd3)

1.30m3(1.70yd3)

1490mm(58.7")

1610mm(63.4")

1.73m3(2.26yd3)

1.50m3(1.96yd3)

1696mm(66.8")

1.85m3(2.42yd3)

1.60m3(2.09yd3)

1800mm(70.9")

0.52m3(0.68yd3)

0.46m3(0.60yd3)

935mm(36.8")

1035mm(40.8")

LONG REACH Standard ◈ : Heavy duty bucket : Rock bucket(Esco type)

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

9. RECOMMENDED OILS Use only oils listed below or equivalent. Do not mix different brand oil. Service point

Kind of fluid

Ambient temperature 。 C (。 F)

Capacity ℓ(U.S. gal)

-20 (-4)

-10 (14)

0 (32)

10 (50)

20 (68)

30 40 (86) (104)

SAE 30 Engine oil pan

19(5.0) Engine oil

SAE 10W

24(6.3) (TIER II)

SAE 10W-30 SAE 15W-40

Swing drive Final drive

Gear oil

7.0(1.8) 11×2 (2.9×2, -#1214) 5.5×2 (1.5×2, #1215-)

SAE 85W-140

ISO VG 32

Tank; 210(55.5) Hydraulic tank

ISO VG 46

Hydraulic oil System; 320(84.5)

ISO VG 68

ASTM D975 NO.1 Fuel tank

Diesel fuel

480(126.8) ASTM D975 NO.2

NLGI NO.1

Fitting (Grease nipple)

Grease

Radiator (Reservoir tank)

Mixture of antifreeze and water 50 : 50

SAE API ISO NLGI ASTM

As required NLGI NO.2

Ethylene glycol base permanent type

50(13.2)

: Society of Automotive Engineers : American Petroleum Institute : International Organization for Standardization : National Lubricating Grease Institute : American Society of Testing and Material

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

CONTROL DEVICES 1. CAB DEVICES 1) The ergonomically designed console box and suspension type seat provide the operator with comfort. 2) ELECTRONIC MONITOR SYSTEM (1) The centralized electronic monitor system allows the status and conditions of the machine to be monitored at a glance. (2) It is equipped with a safety warning system for early detection of machine malfunction.

Horn switch

Switch panel

Breaker operation sw

Cassette & radio

RH control lever

Air vent

Cluster

Speaker

TONE BAL VOL ON

BAND SEEK push

FAD TUNE 1 2 4

PROG 3 5 6

PLL SYNTHES IZER TUNNING

Storage box Seat

Electric box assy CPU controller Resistor Fuse box Master switch Aircon & heater switch One touch decel switch Power max switch Travel lever

LH control lever

Travel pedal

Safety lever

Foot rest

Emergency engine acceleration lever(OPT) (Except TIER II) 29073CD01

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

2. CLUSTER 1) MONITOR PANEL The gauges panel consists of gauges and monitors as shown below, to warn the operator in case of abnormal machine operation or conditions for the appropriate operation and inspection. · Gauges : Indicate operating status of the machine. · Warning lamp : Indicate abnormality of the machine(Red). · Pilot lamp : Indicate operating status of the machine(Amber). ※ The monitor installed on this machine does not entirely guarantee the condition of the machine. Daily inspection should be performed according to chapter 6, Maintenance. ※ When the monitor provides a warning immediately check the problem, and perform the required action.

Monitoring display Fuel gauge

Fuel low level warning lamp Hyd oil temp warning lamp

Hyd oil temp gauge Overheat warning lamp Engine coolant temp gauge Air cleaner warning lamp

CPU controller check warning lamp

Engine oil pressure warning lamp

Power max pilot lamp

Battery charging warning lamp

Preheat pilot lamp

Overload warning lamp Warming up pilot lamp

Engine check lamp (TIER II only)

Decel pilot lamp Coolant level warning lamp

29073CD08

※ The warming lamp lights ON and the buzzer sounds when the machine has a problem. In this case, press the buzzer stop switch and buzzer stop, but the warming lamp lights until the problem is cleared.

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

(1) Monitoring display ① This displays the current time and machine information such as engine rpm, coolant/hydraulic oil temperature, hydraulic oil pressure and also error codes. ※ Refer to the page 4-12 for details.

14073CD03

(2) Fuel gauge

White range 21073CD04

① This gauge indicates the amount of fuel in the fuel tank. ② Fill the fuel when the white range or warning lamp blinks. ※ If the gauge illuminates the white range or warning lamp blinks even though the machine is on the normal condition, check the electric device as that can be caused by the poor connection of electricity or sensor.

(3) Hydraulic oil temperature gauge

Red range 21073CD05

① This indicates the temperature of coolant. ·White range : 30。 C (86。 F ) bel ·Green range : 30-105 。 C (86-221。 ·Red range : 105。 C (221。 F ) above ② The green range illuminates when operating. ③ Keep idling engine at low speed until the green range illuminates, before operation of machine. ④ When the red range illuminates, reduce the load on the system. If the gauge stays in the red range, stop the machine and check the cause of the problem.

(4) Engine coolant temperature gauge

Red range 21073CD05

① This indicates the temperature of coolant. ·White range : 30。 C (86。 F ) below ·Green range : 30-105 。 C (86-221。 F) ·Red range : 105。 C (221。 F ) above ② The green range illuminates when operating. ③ Keep idling engine at low speed until the green range illuminates, before operation of machine. ④ When the red range illuminates, turn OFF the engine, check the radiator and engine.

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

(5) Fuel low level warning lamp ① This lamp blinks and the buzzer sounds when the level of fuel is below 40ℓ(10.6U.S. gal). ② Fill the fuel immediately when the lamp blinks.

21073CD04A

(6) Hydraulic oil temperature warning lamp ① This warning lamp operates and the buzzer sounds when the temperature of hydraulic oil is over 105 。 C( 221 。 F) . ② Check the hydraulic oil level when the lamp blinks. ③ Check for debris between oil cooler and radiator. 21073CD05A

(7) Overheat warning lamp ① This lamp blinks and the buzzer sounds when the temperature of coolant is over the normal temperature 110。 C( 230。 F) . ② Check the cooling system when the lamp blinks.

21073CD06A

(8) Engine oil pressure warning lamp ① This lamp blinks and the buzzer sounds after starting the engine because of the low oil pressure. ② If the lamp blinks during engine operation, shut OFF engine immediately. Check oil level. 21073CD07

(9) Air cleaner warning lamp ① This lamp blinks and the buzzer sounds when the filter of air cleaner is clogged. ② Check the filter and clean or replace it.

21073CD08

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

(10) CPU controller check warning lamp ① Communication problem between CPU controller and cluster makes the lamp blinks and the buzzer sounds. ② Check the communication line between CPU controller and cluster. 21073CD10

(11) Battery charging warning lamp ① This lamp blinks and the buzzer sounds when the starting switch is ON, it is turned OFF after starting the engine. ② Check the battery charging circuit when this lamp blinks, during engine operation. 21073CD13

(12) Overload warning lamp ① When the machine is overload, the overload warning lamp blinks during the overload switch ON.

21073CD15

(13) Engine check lamp(TIER II only) ① This lamp blinks and the buzzer sounds when the communication between CPU controller and ECM on the engine is abnormal. ② Check the communication line between them. 29073CD10

(14) Power max pilot lamp ① The lamp will be ON when pushing power max switch on the LH RCV lever.

21073CD11

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

(15) Decel pilot lamp ① Operating auto decel or one touch decel makes the lamp ON. ② The lamp will be ON when pushing one touch decel switch on the LH RCV lever.

21073CD17

(16) Warming up pilot lamp ① This lamp is turned ON when the coolant temperature is below 30。 C(86 。 F). ② The automatic warming up is cancelled when the engine coolant temperature is above 30 。 C, or when 10 minutes have passed since starting. 21073CD18

(17) Preheat pilot lamp ① This lamp is turned ON when the preheating function is actuated in cold weather. ② Start the engine as this lamp is OFF.

21073CD12

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

2) SWITCH PANEL

Power mode switch

Travel speed switch

User mode switch

Buzzer stop switch Select switch

Auto deceleration switch

21073CD19

(1) Work mode switch

21073CD20

① This switch is to select the machine operation mode, which shifts from general operation mode to heavy operation mode and breaker mode in a raw by pressing the switch. · : Heavy duty work mode · : General work mode · : Breaker operation mode ※ Refer to the page 4-7 for details.

(2) User mode switch ① This switch is to select the maximum power or user mode. ·M : Maximum power ·U : Memorizing operators preferable power setting ※ Refer to the page 4-7 for details. 18073CD21

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

(3) Auto deceleration switch

21073CD22

① This switch is used to actuate the auto deceleration function so the engine speed is lowered automatically when all control levers and pedals are at neutral position to save the fuel. ·Light ON : Auto deceleration function is selected. ·Light OFF : Auto deceleration function is cancelled so that the engine speed increased to previous setting value. ② Operating the auto deceleration function makes the decel indicate lamp on the LCD panel ON.

(4) Power mode switch ① The lamp of selected mode is turned ON by pressing the switch( ), when selecting the power mode to use. ·H : This is used for high power work. ·S : This is used for standard power work. 21073CD23

(5) Travel speed control switch ① This switch is to control the travel speed which is changed to high speed(Rabbit mark) by pressing the switch and low speed(Turtle mark) by pressing again.

21073CD24

(6) Buzzer stop switch

21073CD25

① When the starting switch is turned ON first, normally the alarm buzzer sounds for 2 seconds during lamp check operation. ② The red lamp lights ON and the buzzer sounds when the machine has a problem. In this case, press this switch and buzzer stops, but the red lamp lights until the problem is cleared.

(7) Select switch

21073CD25A

① This switch is used to select the monitor display function. ※ Refer to the page 4-12 for details. ② If the switch is pressed for 3 seconds in time display mode, it moves to time adjusting function, and you can adjust the time as below. ·Hour by auto decel( )switch ·Minute by buzzer stop( ) switch. ③ After time set, the switch is pressed, it returs to clock display.

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

3. SWITCHES

Beacon switch Breaker selection switch Accel dial C

Start switch

Cab light switch Travel alarm switch Preheat switch Washer switch Wiper switch Main light switch

Overload switch Quick coupling switch

TONE

5 BAL

VOL ON

BAND SEEK push

FAD TUNE 1

PROG 3

PLL SYNTHESIZE

Horn switch Breaker operation switch

TUNNING

CAB

Master switch

One touch decel switch Power max switch 29073CD26

1) STARTING SWITCH

21073CD27

(1) There are three positions, OFF, ON and START. · (OFF) : None of electrical circuits activate. · (ON) : All the systems of machine operate. · (START) : Use when starting the engine. Release key immediately after starting. ※ Key must be in the ON position with engine running to maintain electrical and hydraulic function and prevent serious machine damage.

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

2) MASTER SWITCH (1) This switch is used to shut off the entire electrical system. (2) I : The battery remains connected to the electrical system. O : The battery is disconnected to the electrical system. ※ Never turn the master switch to O(OFF) with the engine running. Engine and electrical system damage could result.

13033CD81

3) ACCEL DIAL SWITCH (1) There are 10 dial setting. (2) Setting 1 is low idle and setting 10 is high idle. ·By rotating the accel dial to right : Engine speed increases ·By rotating the accel dial to left : Engine speed decreases

21073CD34

4) MAIN LIGHT SWITCH

Pilot lamp(2nd)

(1) This switch used to operate the head light and work light. ·Press the switch once to head light comes ON. ·Press the switch once more to work light comes ON. ·Press the switch again, return to a first step position. ·Press the switch more than one second to turn off lights.

Pilot lamp(1st) 50073CD28

5) WIPER SWITCH

Pilot lamp(2nd)

(1) This switch used to operate wiper. ·Press the switch once to intermittently operate wiper. ·Press the switch once more to operate wiper low speed. ·Press the switch again return to first step position. ·Press the switch more than one second to turn off wiper.

Pilot lamp(1st) 50073CD29

6) WASHER SWITCH (1) The washer liquid is sprayed and the wiper is operated only while pressing this switch. (2) The indicator lamp is turned ON when operating this switch.

21073CD30

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

7) PREHEAT SWITCH (1) This switch is used for starting the engine in cold weather. If pressed, starting aid fluid injected to get easier engine starting. â&#x20AC;ť Never hold the push button switch for more than 30 seconds, as this can damage the electric valve solenoid. (2) The indicator lamp is turned ON when operating this switch. 21073CD31

8) TRAVEL ALARM SWITCH (1) This switch is to activate travel alarm function surrounding when the machine travels to forward and backward. (2) On pressing this switch, the alarm operates only when the machine is traveling.

21073CD32

9) CAB LIGHT SWITCH(Option) (1) This switch turns ON the cab light on the cab.

21073CD33

10) OVERLOAD SWITCH (1) When this switch turned ON, buzzer makes sound and overload warning lamp comes ON in case that the machine is overload. (2) When turn OFF buzzer stops and warning lamp goes out.

21073CD35

11) QUICK CLAMP SWITCH(Option) (1) This switch is used to engage or disengage the moving hook on quick clamp. â&#x20AC;ť Refer to the page 8-6 for details.

29073CD36

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

12) BREAKER SELECTION SWITCH(Option) (1) This switch is used to select breaker. â&#x20AC;» The breaker operates only when this switch is selected.

21073CD37

13) BEACON SWITCH(Option) (1) This switch turns ON the rotary light on the cab. (2) The below indicator lamp is turned ON when operating this switch.

21073CD38

14) HORN SWITCH Horn switch

(1) This switch is at the top of right side control lever. On pressing, the horn sounds.

RH RCV-lever 21073CD39

15) BREAKER OPERATION SWITCH (1) On pressing this switch, the breaker operates only when the breaker selection switch on the switch panel is selected.

Breaker operation switch

RH RCV-lever 21073CD39A

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

16) ONE TOUCH DECEL SWITCH One touch decel switch

(1) This switch is used to actuate the deceleration function quickly. (2) The engine speed is increased to previous setting value by pressing the switch again.

LH RCV-lever 21073CD40

17) POWER MAX SWITCH (1) This switch activate power max function. When this switch is kept pressed, hydraulic power of work equipment will increased approx 110 percent during 8 seconds.

Power max switch

LH RCV-lever 21073CD40A

(2) After 8 seconds, function is cancelled automatically even switch is keep pressed. â&#x20AC;» Don not use for craning purposes.

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

4. LEVERS AND PEDALS RH control lever

TONE BAL VOL ON

BAND SEEK push

FAD TUNE 1 2 4

PROG 3 5 6

PLL SYNTHES IZER

TUNNING

LH control lever Safety lever Travel lever

Emergency engine acceleration lever(OPT) (Except TIER II)

Travel pedal

29073CD41

1) LH CONTROL LEVER (1) This joystick is used to control the swing and the arm. (2) Refer to operation of working device in chapter 4 for details.

21073CD42

2) RH CONTROL LEVER (1) This joystick is used to control the boom and the bucket. (2) Refer to operation of working device in chapter 4 for details.

21073CD43

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

3) ENGINE ACCELERATION LEVER FOR EMERGENCY(Option, except TIER II) (1) This lever is used to increase or reduce the rotation speed of engine when the abnormality is occurred in the CPU controller. Select the prolix switch to EMERGENCY.

21073CD44

(2) Press the button and pull the lever to increase or push the lever to reduce the rotation speed, then put the lever on the position you want. When stopping the engine, turn the key to OFF and push the acceleration lever completely down.

※ METHOD OF CONNECTING EMERGENCY ENGINE ACCELERATION LEVER(Opt, except TIER II) (1) Open engine hood and disconnect rod from throttle lever at a A point. Engine throttle lever A Cable

(2) Connect emergency engine acceleration cable to throttle lever at B point.

B Low idle position

High idle position

29073CD66

4) EMERGENCY ENGINE STARTING CONNECTOR (1) If the CPU controller is removed, the engine does not start. (2) Before starting the engine, connect the connector CN-92 A with B. ※ Do not connect these connectors when the CPU is not removed. A B

CN-92

29073CD79

5) SAFETY LEVER (1) All control levers and pedals are disabled from operation by locating the lever to lock position as shown. ※ Be sure to lower the lever to LOCK position when leaving from operator's seat. Unlock Lock 29073CD45

(2) By pulling lever to UNLOCK position, machine is operational. ※ Do not use the safety lever for handle when getting on or off the machine.

6) TRAVEL LEVER (1) This lever is mounted on travel pedal and used for traveling by hand. The operation principle is same as the travel pedal. (2) Refer to traveling of the machine in chapter 4 for details.

21073CD46

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

7) TRAVEL PEDAL (1) This pedal is used to move the machine forward or backward. (2) If left side pedal is pressed, left track will move. If right side pedal is pressed, right track will move. (3) Refer to traveling of machine in chapter 4 for details. 21073CD46A

8) SEAT AND CONSOLE BOX ADJUST LEVER (1) This lever is used to move the seat and console box to fit the contours of the operator's body. (2) Pull the lever to adjust forward or backward over 170mm(6.7"). Adjust lever 21073CD47

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

5. AIR CONDITIONER AND HEATER Air conditioner and heater are equipped for pleasant operation against outside termperature and defrost on window glass. Ã&#x201A;Location of air flow ducts

A A

C B

Inlet change over switch Oulet change over switch Temperature control switch Fan speed switch Air conditioner switch

21073CD48

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

1) POWER SWITCH (1) This switch makes the system and the LED simultaneously ON or OFF. (2) Default setting values Function

Air conditioner Fan speed Temperature Outlet

Value

OFF

Max cool

Face

Inlet Recirculation

21073CD53

2) AIR CONDITIONER SWITCH(Compressor switch) (1) Operating this switch turns the compressor and the LED simultaneously on or off.

21073CD53

(2) In accordance with the evaporator temperature, compressor turns on or off automatically without changing LED stare. â&#x20AC;ť Air conditioner operates to remove vapor and drains water through a drain hose. Water can be sprayed into the cab in case that the vacuum valve of drain hose has a problem. In this case, exchange the vacuum valve.

3) FAN SPEED SWITCH (1) It is possible to control the fan to four steps. (2) The first step or the fourth step gives 5 times beeps.

21073CD52

4) TEMPERATURE CONTROL SWITCH (1) There are 9 steps to control temperature from max cool to max warm controlled up and down by 1 step. (2) Max cool and max warm arouse 5 times beeps. Cool Warm 21073CD50

(3) For the max warm or the max cool it's better to be configured as following table. Temperature

Air conditioner

Fan speed

Outlet

Inlet

Max cool

Face

Recirculation

Max warm

OFF

Foot

Fresh

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

5) OUTLET CHANGE OVER SWITCH (1) There are four steps of air flow. Mode Switch position A 21073CD51

Outlet

B C

(2) When defroster switch operating, INLET switch turns to FRESH mode and air conditioner switch turns ON. (3) In case of heating range(5~Max warm), air conditioner won't turns ON. 6) INLET CHANGE OVER SWITCH

Fresh Recirculation 21073CD49

(1) It is possible to change the air-inlet method. ① Fresh Inhaling air from the outside to pressurize cab inside. ※ Check out the fresh air filter periodically to keep a good efficiency. ② Recirculation It recycles the heated or cooled air to increase the energy efficiency. ※ Change air occasionally when using recirculation for a long time. Check out the recirculation filter periodically to keep a good ※ efficiency. Recirculation function operates when the system is OFF but it can (2) be changed whenever needed.

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

ÿ AUTO AIR CONDITIONER AND HEATER(OPTION) Auto air conditioner and heater system automatically keeps the optimum condition in accordance with operator's temperature configuration sensing ambient and cabin inside temperature.

ÂLocation of air flow ducts

TONE BAL VOL ON

BAND SEEK

TUNE 1

PROG 3

PLL SYNTHES IZER TUNNING

A A

SPARE

20A

FUSE HOLDER

B CA

RE LAMP CABIN LAMP LAMP

BEACON

SPARE

WORK F/PUMP LAMP

KEY

20A

HEAD

& HEATER

FUEL 3

START MOTOR LAMP

2 LIGHT

SOL.

& HEATER

SOLENOID

CIGAR

SAFETY

1 - HEAT

PANEL PRE

MOTOR

SOLENOID

SWITCH

WIPER

10A 20A

SOLENOID

HONE

WIPER

BOOM

CUT-OFF

TRAVEL

CONVERTO

FUEL

HONE

PANEL

SWITCH

CLUSTER

-2

COMP RY

C/RADIO

POWER

-7

ETHER CR

- 36

- 35 Y RY

SAFET CR

-5

C B

Switch panel Fresh air switch

LCD

Mode switch

Auto switch

Power OFF switch

Fan speed switch Air recirculation switch

Air conditioner switch Temperature control switch 3607A3CD48

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

1) POWER OFF SWITCH (1) This switch makes the system and the LED OFF. Just before the power OFF, setted values are stored. (2) Default setting values Function Air conditioner In/outlet Value

OFF

Inlet

LCD OFF

Temperature

Mode

Previous sw OFF Previous sw OFF

370073CD54

2) AUTO SWITCH (1) Turn the starting switch to ON position, LCD lights ON. Auto air conditioner and heater system automatically keeps the optimum condition in accordance with operator's temperature configuration sensing ambient and cabin inside temperature. (2) This switch can restart system after system OFF. 370073CD52

3) AIR CONDITIONER SWITCH(Compressor switch) (1) This switch turns the compressor and the LCD ON.

370073CD53

(2) In accordance with the temperature sensed by duct(evaporator) sensor, compressor turns ON or OFF automatically. ö Air conditioner operates to remove vapor and drains water through a drain hose. Water can be sprayed into the cab in case that the drain cock at the ending point of drain hose has a problem. In this case, exchange the drain cock.

4) FAN SPEED SWITCH (1) Fan speed is controlled automatically by setted temperature. (2) This switch controlls fan speed manually. Â There are 8 up/down steps to control fan speed. Â The maximum step or the minimum step beeps 5 times.

370074CD56

(3) This switch makes the system ON. ā : First step(AUTO) ă :First step(Manually)

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

5) TEMPERATURE CONTROL SWITCH (1) Setting temperature indication(17~32Á C, Scale : 1Á C) (2) Max cool and max warm beeps 5 times. (3) The max cool or the max warm position operates as following table.

370074CD57

Temperature

Compressor

Fan speed

In/Outlet

Mode

Max cool

Max(Hi)

Recirculation

Vent

Max warm

OFF

Max(Hi)

Fresh

Foot

6) MODE SWITCH (1) Operating this switch, it beeps and displays symbol of each mode in order.(Vent Ą B/L Ą Foot Ą Def Ą Vent) Vent

B/L

Foot

Defroster

Mode switch A

370074CD50

Outlet

B C

(2) When defroster switch operating, FRESH AIR/AIR RECIRCULATION switch turns to FRESH AIR mode and air conditioner switch turns ON. (3) When this switch ON, the system operates with previous configuration.

7) FRESH AIR/AIR RECIRCULATION SWITCH

36073CD58

(1) It is possible to change the air-inlet method. Η Fresh air( ) Inhaling air from the outside. ö Check out the fresh air filter periodically to keep a good efficiency. Θ Air recirculation( ) It recycles the heated or cooled air to increase the energy efficiency. ö Change air occasionally when using recirculation for a long time. ö Check out the recirculation filter periodically to keep a good efficiency.

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8) SELF DIAGNOSIS FUNCTION (1) Procedure Starting switch ON

Press the air recirculation button over 5 times within 2 secondsduring pressing the AUTO switch All symbol of LCD blink 5 times

Error check

Switch OFF

System OFF

Press AUTO switch Cancelled diagnosis function(normal function) 3607A3CD69

(2) Error check Â The corresponding error code flickers on the setup temperature display panel, the other symbol will turn OFF. Â Error code flickers every 0.5 second. Â If error code is more than two, each code flickers 2 times in sequence. Â Error code Error code

Description

Error code

Description

Ambient sensor

Duct(evaporator) sensor

Cabin inside sensor

Temp actuator

Coolant temp sensor

Mode actuator

(3) Fail safe function Error description

Fail safe function

Ambient sensor(11)

Á C alternate value control

Cabin inside sensor(12)

Á C alternate value control

Coolant temp snesor(13)

More than 10 minutes after engine start up, the alternate vaule is ON

Duct(evaporator) snesor(14)

Á C alternate value control

Temp actuator(15)

If opening amount is 0%, the alternate value is 0% If not, the alternate value is 100%

Mode actuator(16)

The alternate value is Vent

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6. OTHERS Cassette & radio remote controller

Cassette & radio BAL TONE

VOL ON

push

FAD 1

FAD TUNE

2 4 3 PROG

Seat

PLL SYNTHESI ZER TUNNING

12V socket

EMERGENCY

SPARE

LAMP

SPARE

CABIN LAMP LAMP

BEACON

SPARE

WORK

3 MOTOR LAMP BOOM

HONE

WIPER

SOLENOID

SOL. AC

& HEATER

SAFETY

1 - HEAT

PANEL PRE

MOTOR

SOLENOID

SWITCH

WIPER

CUT-OFF

TRAVEL

CONVERTOR

FUEL

HONE

RY AC RY POWER CR

COMP RY CR

-7

ETHER CR

- 36

- 35 RY

SAFETY CR

-5

CN-47

CN-19&19B CN-19A

CN-92A CN-92B CN-16&16B CN-16A

Prolix resistor CN-47

Machine control unit

Cigar lighter

CN-19&19A CN-19B

Service meter

CN-92A CN-92B

CN-16&16A CN-16B

Fuse box

Emergency engine starting connector Emergency engine speed connector J1939 serial connector RS232 serial connector 36073CD54

1) CASSETTE AND RADIO(~#1532) High performance audio system is equipped for pleasant operation. Left/Right speaker Tape Volume controller Winding/Rewinding button Eject button Tone controller Band button Cassette tape inserter BAL

BAS

PROG

TRE

BAND

HYUNDAI

ON VOL

SEEK

Power switch Volume switch TUNE

Seek button

MTL

Tune Pre-set buttons button

AUTO REVERSE

Displayer 20W03CD08

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(1) Power and volume switch ON VOL

20W03CD09

① This switch is turned to right, power will be turned ON and the sound is increased. ② If it is turned to left, volume will be decreased and power will be turned OFF. ※ The volume controller of the cassette radio does not operate when turning ON the remote controller power.

(2) Seek button ① If this seek button is pressed, the radio automatically stops at the next frequency of broadcasting for your listening.

SEEK

TUNE 20W03CD10

(3) Tune button SEEK

TUNE 20W03CD11

① Whenever you press " + " button, higher channels are selected. ② Whenever you press " - " button, lower channels are selected. ③ General AM band : Frequency changes in 9kHz between 531 to 1602kHz. FM band : Frequency changes in 0.1MHz between 87.5 to 108.0MHz. ④ America AM band : Frequency changes in 10kHz between 530 to 1710kHz. FM band : Frequency changes in 0.2MHz between 87.9 to 107.9MHz. ⑤ Europe LW band : Frequency changes in 9kHz between 153 to 279kHz. MW band: Frequency changes in 9kHz between 522 to 1620kHz. FM band : Frequency changes in 0.05MHz between 87.5 to 108.0MHz.

(4) Pre - set button

MTL

20W03CD12

① You can immediately listen to the station by pressing pre-set button for which broadcasting station is pre-set. ② How to set broadcasting in memory. ·You can pre-set 6 stations each AM/FM band. ·When you want the station to be set in memory, press selected pre-set button for more than 2 seconds.

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(5) Displayer ① General and America ·When radio is turned ON, stereo, AM, FM, FM2, MTL and reception frequency are displayed. ② Europe ·When radio is turned ON, stereo, LW, MW, FM, FM2, MTL and reception frequency are displayed. ③ When cassette tape is played, indicator arrow( , ) are displayed. 20W03CD13

(6) Left/Right speaker volume button ① If balance button is pressed, it will spring out. BAL Volume of right and left speakers will be adjusted by turning the button to right or left. ② It will be fixed by pressing again after adjustment. 20W03CD15

(7) Tone button BAS

TRE

20W03CD14

① BASS tone If tone button is pressed, it will spring out. If it is turned to right, BASS tone is increased, and if it is turned to left, BASS tone is decreased. ② TREBLE tone You can adjust the TREBLE tone by pull out the button. If it is turned to right, TREBLE tone is increased, and if it is turned to left, TREBLE tone is decreased. ③ It will be fixed by pressing again after adjustment.

(8) Band button ① You can listen to broadcasting on AM or FM band by pressing this band selection button. BAND 20W03CD16

(9) Tape winding/Rewinding button ① If you press this button once while the tape is playing the direction PROG will be reversed. ② If you press one of these buttons the tape will be winding fast or rewinding, and if you press another button on a certain point, the tape will be played. 20W03CD17

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2) REMOTE CONTROLLER(Cassette and radio)

Band button ON OL V

Seek button

Power and volume switch 29073CD62

(1) Power and volume switch

ON VOL

29073CD67

① This switch is turned to right, power will be turned ON and the sound is increased. ② If it is turned to left, volume will be decreased and power will be turned OFF. ※ This switch does not operate when turning ON the cassette radio power.

(2) Seek button ① If this seek button is pressed, the radio automatically stops at the next frequency of broadcasting for your listening. SEEK

29073CD68

(3) Band button ① You can listen to broadcasting on AM or FM band by pressing this band selection button. BAND

29073CD69

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3) SEAT The seat is adjustable to fit the contours of the operator's body. It will reduce operator fatigue due to long work hours and enhance work efficiency. (1) Forward/Backward adjustment(A) ① Pull lever A to adjust seat forward or backward. ② The seat can be moved forward and backward over 170mm(6.7") in 9 steps. (2) Upward/Downward adjustment(B) ① Pull lever B to adjust seat upward or downward. ② Forward or backward side adjustment only can be made, tilting to one side, by moving lever B respectively. B

(3) Reclining adjustment(C) Pull lever C to adjust seat back rest. (4) Arm rest adjustment(E) This can be adjusted by pushing the button E to right and left.

(5) Head rest adjustment (D) This is adjustable vertically to fit operator's requirements.

(6) Cushion adjustment (F) Adjust the handle to the operator's weight. C F A 95W33CD16

Always check the condition of the seat belt and mounting hardware before operating the machine. Replace the seat belt at least once every three years, regardless of appearance.

4) CIGAR LIGHTER (1) This can be used when the engine starting switch is ON.

13033CD69

(2) The lighter can be used when it springs out in a short while after being pressed down. ※ Service socket Use cigar lighter socket when you need emergency power. Do not use the lighter exceeding 24V, 100W.

5) 12V SOCKET(Option)

(1) Utilize the power of 12V as your need and do not exceed power of 12V, 30W.

29073CD60

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

FUSE HOLDER

에어콘 콤프 릴레이

전원 릴레이

안전 릴레이

20A

PRE-HEAT

10A

CIGAR LIGHT

10A

예열

HORN

10A

담배 라이트

AC & HEATER

연료펌프

솔레노이드3

경적

BEACON LAMP

예비용

안전솔레노이드

10A

에어콘, 히터

CABIN LAMP

SPARE

예비용

솔레노이드1

카세트라디오

10A

중앙처리장치

10A

변압기

C/RADIO

스위치 판넬

경광등

20A

CPU

연료차단장치

운전실

10A

CONVERTOR

와이퍼 모터

WORK LAMP

작업등

10A

SPARE

예비용 SWITCH PANEL

전조등

10A

클러스터

10A

에어콘

20A

중앙처리장치

20A

CLUSTER

와이퍼 모터

FUEL CUT-OFF

AC BLOWER

에어콘, 히터

WIPER MOTOR

CPU

실내등

HEAD LAMP

10A

WIPER MOTOR

시동키

AC & HEATER

SPARE

ROOM LAMP

20A

예비용

20A

START KEY

10A

예비용

SPARE

6) FUSE BOX

주행

SPARE

FUEL F/PUMP

(1) The fuses protect the electrical parts and wiring from burning out. (2) The fuse box cover indicates the capacity of each fuse and circuit it protects. ※ Replace a fuse with another of the same capacity. Before replacing a fuse, be sure to turn OFF the starting switch.

SOLENOID 3

SAFETY SOL

SOLENOID 1

TRAVEL

경적 릴레이

에테르 릴레이

29073CD55

전원 릴레이

재시동 방지

FUSE HOLDER

에어콘 콤프 릴레이

30A

HORN

10A

AC & HEATER

경적

BEACON LAMP

10A

에어콘, 히터

CABIN LAMP

안전솔레노이드

솔레노이드1

경광등

WORK LAMP

솔레노이드3

주행

10A

운전실

HEAD LAMP

연료 펌프

예열

10A

ECM

엔진컨트롤러

10A

클러스터

10A

CLUSTER

카세트라디오

10A

C/RADIO

중앙처리장치

작업등

10A

CPU

변압기

전조등

20A

15A

CONVERTOR

WIPER MOTOR

와이퍼 모터

10A

엔진컨트롤러

예비용

SPARE

중앙처리장치

ECM

와이퍼 모터

스위치 판넬

CPU

에어콘, 히터

SWITCH PANEL

10A

WIPER MOTOR

에어콘, 히터

엔진컨트롤러

20A

AC & HEATER

실내등

ECM

10A

AC & HEATER

시동키

ROOM LAMP

10A

SPARE

20A

START KEY

30A

예비용

20A 10A SPARE

FUSE BOX(TIER II only)

담배 라이트

FUEL F/PUMP

SOLENOID 3

SAFETY SOL

SOLENOID 1

TRAVEL

PRE-HEAT

CIGAR LIGHT

경적 릴레이

에테르 릴레이

29073CD56

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

7) CPU CONTROLLER (1) To match the engine torque with the pump absorption torque, CPU controller varies EPPR valve output pressure, which control pump discharge amount whenever feedbacked engine speed drops under the reference rpm of each mode set.

LED

(2) Three LED lamps on the CPU controller display as below.

MO PA DE RT L:R NO OB :21 EX N8 290 -32 LC 10 -7 2

LED lamp

29073CD72

Trouble

Service -

G is turned ON

Normal

G and R are turned ON

Trouble on CPU or ROM · Change the controller

G and Y are turned ON

Trouble on serial communication line

· Check if serial communication lines between controller and cluster are disconnected

Three LED are turned OFF

Trouble on CPU controller power

· Check if the input power wire (24V, GND) of controller is disconnected · Check the fuse

G : green,

R : red,

Y : yellow

8) PROLIX RESISTOR(Option)

Prolix resistor

(1) This resistor is used to continuous working case of malfunction of the CPU controller. ·Normal : CN-19 connect with connector CN-19A ·Emergency : CN-19 connect with connector CN-19B

CN-19 CN-19B CN-19A

※ Never connect connector CN-19 with connector CN-19B when CPU controller is in normal operation.

50073CD45

9) EMERGENCY ENGINE SPEED CONTROL NORMAL CN-16A

(1) When the CAN commucation between the ECM and the CPU controller is abnormal due to malfunction of the CPU controller, change CN-16 connection from CN-16A to CN-16B and then control the engine speed by rotating accel dial switch.

CN-16 CN-16B

EMERGENCY 45073CD44

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

10) SERVICE METER (1) This meter shows the total operation hours of the machine. (2) Always ensure the operating condition of the meter during the machine operation. Inspect and service the machine based on hours as indicated in chapter 6, maintenance. 13033CD72

11) RS232 SERIAL CONNECTOR (1) CPU controller communicates the machine data with Lap top computer through RS232 connector.

29073CD59

12) UPPER WINDSHIELD

14073CD70

Latch 2

(1) Perform the following procedure in order to open the upper windshield. ① Release both latches(1) in order to release the upper windshield. ② Hold both grips that are located at the bottom of the windshield frame and at the top of the windshield frame push the windshield upward. ③ Hold both grips that are provided on the windshield frame and back into the storage position until auto lock latch(2) is engaged, move the levers of both latches(1) into the locked position. Push the levers toward the rear of the cab in order to hold the windshield in storage position.

(2) Perform the following procedure in order to close the upper windshield. ① Move the lever of the auto lock latch(2) in the direction of the arrow in order to release the auto lock latch. ② Reverse step ① through step ③ in order to close the upper windshield.

29073CD71

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13) RADIO AND CASSETTE(Standard, #1533~) 8

SOUND

MUTE

VOLUME

JAZZ VOCAL POP CLASSIC ROCK FLAT LOUD TA AF AST

DISC PRESET

BAND

VOLUME

TAAF

321

AST RDS

6 12

11 12

7807A3CD81

RADIO AND CD PLAYER(Option) 8

4x35W

SOUND

MUTE

RND

VOLUME

JAZZ VOCAL POP CLASSIC ROCK FLAT LOUD TA AF AST

DISC PRESET

BAND AST

RPT

SCN

TAAF

VOLUME

321

4 5

6 12

SOURCE RDS

11 12

7807A3CD82

â&#x2013; FRONT PANEL PRESENTATION 1 2 3 4 5 6 7 8

9 10

- - - - - - - - Preset button 1 1 RND - - - - - - - - - - - - CD random playback on/off - - - - - - - - Preset button 2 2 RPT - - - - - - - - - - - - CD repeat track on/off - - - -3- - - - - - - - - - - - - Preset button 3 SCN - - - - - - - - - - - - CD's track scan 4 - - - - - - - - Preset button 4 - - - -5- - - - - - - - - - - - - Preset button 5 TA AF - - - - - - - - Short press : TA on/off Long press : AF on/off SOUND - - - - - - Select sound/audio styles - - - - - - - - - - - - Short press : power on Long press : power off MUTE - - - - - - - - Short press : To mute or cancel mute. - - - - - - - - - - - - - - - - - - - - - Display - - - - - - - - - - - - - - - - - - - - - Volume knob : Press up/down to adjust the volume ; adjust selected audio mode

11 SOURCE - RDS - - - - - - - - - BAND - - - - - - AST - - - - - - - - - - -

Short press : Change source(Radio/CD) Long press : RDS on/off Short press : To select band Long press : Autostore(CD) Short press : Autostore(Cassette) 12 - - - - - - - - - - Tuner mode Short press : Auto search up/down Long press : Manual search up/down Cassette mode : No function CD mode Short press : Next/previous track Long press : Fast forward or fast rewind 13 - - - - - - - - - - - Fast forward(cassette deck) 14 - - - - - - - - - - - Fast rewind(cassette deck) 15 - - - - - - - - - - - Disc eject(CD) Eject cassette 16 - - - - - - - - - - - - - - - - - - - CD opening / Cassette opening

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

■AUDIO (1) Power and mute button

MUTE

7807A3CD09

① POWER ON/OFF Press to switch on the set. Press for more than 2 seconds to switch off the set. ② MUTE(Silence) Short press key to mute or cancel the mute(silence). ※ The silence period may be interrupted by ALARM announcement or traffic announcement messages(If TA is switched on).

(2) Volume button ① Press the volume button up/down to adjust the volume. Please make sure you can still hear the traffic(horns, sirens..).

VOLUME

7807A3CD11

(3) Sound button

SOUND

7807A3CD10

① SOUND Whether you listen to Jazz, Vocal, Pop, Classic or Rock music, the SOUND button is the perfect setting for your choice. · Press SOUND then the sound button to select BASS-Treb for your own sound style, or adjust the settings with the volume up/down buttons to select one of the pre define sound styles: - BASE -TRE - FLAT - JAZZ - VOCAL - POP - CLASSIC - ROCK

: Your own settings of bass and treble. : Original : Jazz music : Speech : Pop music : Classical music : Rock music

② AUDIO SETTING · Press SOUND to select desired audio mode. · Adjust the settings with the volume up/down buttons : - Sound style : BASS-TRE, FLAT, JAZZ, VOCAL, POP, CLASSIC, ROCK - BASS : Low notes - TREBLE : High notes - BALANCE : Left-right - FADER : Rear-front - LOUD : OFF, LOW, MID, HIGH · Press the volume button to adjust the selected audio mode. After 5 seconds the display goes back to the last mode of operation. Adjustment of Bass and Treble settings is only possible when BASS-TRE is selected as the sound style. 3-29

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

(4) Source button BAND AST

SOURCE RDS

7807A3CD13

① Press SOURCE to select the desired source : - TUNER - CD ※ Products with cassette mechanism will change source to cassette only when a tape is inserted.

■RADIO (1) Wave band / Automatic search button BAND AST

SOURCE RDS

7807A3CD13

① WAVEBAND · Press BAND to select the desired band: FM I LW

FM II MWAST(AMAST)

FM AST MW I

② AUTOMATIC SEARCH Use search tuning to automatically search for a station. · Press to tune a station of a lower frequency or to a higher frequency. · To search for another station, press the key again. ③ MANUAL TUNING(If you know the frequency of the required station) · To switch to manual tuning : Long press the search button or for more than 2 seconds will switch the tuning to manual tuning. · Then press to tune to a station of a lower frequency or to a higher frequency. · When keys are released, a time-out start to count. After 5 seconds time-out, display 'Auto' for one second and return to automatic search.

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

(2) Preselected button Preselected stations 1

TAAF 7807A3CD14

① Manually storing stations in a preset Five stations per band can be stored and recalled using the preset keys(1 to 5). Tune in to the desired station. · Press the desired preset key(1 to 5) for more than 2 seconds to · store the current tuned station. When storing an FM station, the current program station name and the AF mode are stored on the preset(Some stations use alternating program service name). ② Recalling a preset Press the desired preset key(1 to 5) to recall the stored station. ③ Automatically storing stations(AUTO-STORE) You can automatically store 5 strongest FM stations on the FM AST band or 5 strongest MW(AM) stations on the MW(AM) AST band. When you use Auto store, the new stations replace any stations previously stored in the FM AST band or the MW(AM) AST band. · Press AST to activate autostore. · The set gives a beep and then mutes. · When it has finished, you hear a beep followed by the station stored on preset 1. · Sometimes it may not be possible to find 5 stations.

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RADIO DATA SYSTEM(RDS) ON FM ■R More and more stations broadcasts RDS informations in order to offer you many advantages including:

TA AF 7807A3CD15

(1) Program service name(PS) Allows the radio to display the name of the station instead of its frequency. (2) Automatic returning(AF) The set remains tuned to the current station by continually searching the best alternative frequency for best reception. You can switch AF off. - Activate/Deactivate AF This set continuously search for other alternative frequencies for the tuned radio station and automatically selects the best frequency for reception. Long press TA for more than 2 second to activate/ deactivate AF. AF

(3) Alarm messages(PTY ALARM) This set automatically receives emergency messages made by the broadcaster. · During the messages the display shows 'ALARM' and the stationname alternately. (4) Traffic announcements(TA) You can activate the TA modes to give priority so as to hear traffic announcements related to these subjects(even if you play a cassettes/CD or mute the set). - Activate/Deactivate TA · Short press BAND to select an FM band. · Press TA to activate/deactivate TA. - If you activate TA mode · You will hear the traffic announcements when broadcast by station(even if you play a cassette/CD or mute the set). · If the tuned station does not enable the reception of traffic announcements, the display shows 'NO TA'. The radio automatically searches and appropriate station. - Interrupting traffic announcement mode If you do not wish to continue listening to a particular traffic announcement key to interrupt traffic announcement without · Short press TA switching off the mode · The set will return to the previous operating mode. ※ You can switch off RDS features if not required. · Long press RDS key to switch off RDS. · All RDS related features e.g., TA, etc...will be deactivated when RDS is switch off. AF

BAND AST

SOURCE RDS

7807A3CD13

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

■CASSETTE PLAYER (1) Winding/Rewinding button

7807A3CD12

※ Only use good quality cassettes. ※ To avoid possible tape damage always take out the cassette after use. Protect your cassettes. Put them back in their boxes immediately after use. ※ Never expose cassettes to heat or direct sunlight. ① Play back Slide the cassette, with the open side to the right into the cassette opening. Playback starts. The direction of playback is shown by indicator . ② Stopping playback( ) · To stop playback, Press the button fully home. · The unit will switch over to radio reception. · The cassette is partially ejected. ③ Reverse(before the end of the tape) Press the and buttons at the same time halfway in. ④ Fast rewind / Fast forward( or ) The direction of fast winding depends on the direction of play indicated on the display. Display during playback

Action

Key to press

Fast forward Fast rewind Fast forward Fast rewind During fast forward or rewind the radio resumes. If you continue fast winding until the end of the tape, play back restarts automatically. ⑤ To stop fast winding To stop fast winding before the end of the tape, press the key which is not pressed( or ). Playback is then resumed. ⑥ End of the tape At the end of the tape, playback continues in the revers direction. ⑦ Maintenance After extended use of the cassette player, dust, contamination or grime can accumulate on the playback head. This results in diminishing high-note reproduction. This can be remedied using a cleaning cassette(one or twice a month) and playing it through like an ordinary cassette.

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

■CD PLAYER (1) Winding / Rewinding button BAND AST

SOURCE RDS

7807A3CD13

① CD playback This CD player is suitable only for 12cm disc, do not use irregular shaped CD. · Slide the disc into the slot with label facing upwards. Playback starts. · If a disc is already inserted : Press SOURCE to select CD as the source. Playback starts. ② Previous / Next track( or ) · Short press the or button to select the desired track. · Playback resume with the chosen track. ③ Fast rewind / Fast forward( or ) · Long press the or button for more than 2 seconds to quickly move rewind or forward through the disc. · Normal play back resumes when you release the button.

RND

④ Random track playback · Press RND to activate / deactivate random track playback.

RPT

⑤ Repeat track · Press RPT to activate / deactivate repeat current track.

SCN

⑥ Scan track The scan function enables you to listen to the first few seconds of each track. · Press SCN to activate / deactivate scan track. ⑦ Disc eject · Press to eject the disc.

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AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

■RADIO SETTING

JAZZ VOCAL POP CLASSIC

ROCK FLAT LOUD TA AF AST

(1) AMERICA Press , No. 1 and No. 4 buttons at the same time. completes displaying " AMERICA". (2) SOUTH AMERICA Press , No. 2 and No. 5 buttons at the same time. completes displaying " SOUTH". (3) ASIA Press , No. 1 and No. 5 buttons at the same time. completes displaying " ASIA". (4) EUROPE Press power, No. 2 and No. 4 buttons at the same time. completes displaying " EUROP".

PRESET

7807A3CD16

Set up

14) REMOTE CONTROLLER

7 4507A3CD90

(1) Power ON/OFF button ① Press to switch ON the set. Press switch OFF the set.

4507A3CD81

(2) Volume button(up) ·Short press : Volume up one step ·Long press : Volume up continuous

4507A3CD82

3-35

for more than 2seconds to

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

(3) Volume button(down) ·Short press : Volume down one step ·Long press : Volume down continuous.

4507A3CD83

(4) Source & mute button ·Short press : Change source(Radio/CD) ·Long press : To mute or cancel mute.

4507A3CD84

(5) Next button

4507A3CD85

① Tuner mode ·Short press : Preset up ·Long press : Band up ② Cassette mode ·Short press : Reverse(before the end of the tape) ·Long press : No function ③ CD mode ·Short press : Track 1 ·Long press : Scan track

(6) Search button(up)

4507A3CD86

① Tuner mode ·Short press : Search up one step ·Long press : Search up continuous ② Cassette & CD mode ·Short press : Next track ·Long press : Fast forward

(7) Search button(down)

4507A3CD87

① Tuner mode ·Short press : Search down one step ·Long press : Search down continuous ② Cassette & CD mode ·Short press : Previous track ·Long press : Fast rewind

3-36

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

OPERATION 1. SUGGESTION FOR NEW MACHINE 1) It takes about 100 operation hours to enhance its designed performance. 2) Operate according to below three steps and avoid excessive operation for the initial 100 hours. Avoid excessive operation for initial 100 hours

Service meter

Load

Until 10 hours

About 60%

Until 100 hours

About 80%

After 100 hours

100%

Excessive operation may deteriorate the potential performance of machine and shorten lifetime of the machine. 3) Be careful during the initial 100 hours operation (1) Check daily for the level and leakage of coolant, engine oil, hydraulic oil and fuel. (2) Check regularly the lubrication and fill grease daily all lubrication points. (3) Tighten bolts. (4) Warm up the machine fully before operation. (5) Check the gauges occasionally during the operation. (6) Check if the machine is operating normally during operation. 4) Replace followings after initial 50 hours of operation Checking items

Service

Engine oil Engine oil filter element Hydraulic oil return filter element Hydraulic oil tank drain filter cartridge

Replace

Line filter element Fuel filter

4-1

29074OP01

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

2. CHECK BEFORE STARTING THE ENGINE 1) Look around the machine and under the machine to check for loosen nut or bolts, collection of dirt, or leakage of oil, fuel or coolant and check the condition of the work equipment and hydraulic system. Check also loosen wiring, and collection of dust at places which reach high temperature. Refer to the daily check on the chapter 6, maintenance.

Check before starting

2) Adjust seat to fit the contours of the operator's body for the pleasant operation. 3) Adjust the rear view mirror.

21074OP02

4-2

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

3. STARTING AND STOP THE ENGINE 1) CHECK INDICATOR LIGHTS (1) Check if all the operating lever is on the neutral position. (2) Turn the starting switch to the ON position, and check following. If all the lamps light ON and buzzer sounding for 2 seconds. After lamp check CL : 1.4 , the version of cluster program, is displayed on Monitoring display(3) for 5 seconds and the cluster returns to default. Only below lamps will light ON and all the other lights will turn OFF after 2 seconds. Battery charging warning lamp(2) Engine oil pressure warning lamp(1) Refer to the START PROCEDURE on the page 0-13

START OFF

1 2

21074OP03

2) STARTING ENGINE IN NORMAL TEMPERATURE Sound the horn to warn the surroundings after checking if personnel or obstacles are in the area. (1) Turn the starting switch to START position to start the engine. If the engine does not start, allow the starter to cool for about 2 minutes before attempting to start the engine again. (2) Release the starting switch instantly after the engine starts to avoid possible damage to the starting motor.

29074OP04

4-3

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

3) STARTING ENGINE IN COLD WEATHER Sound horn to warn surroundings after checking if there are obstacles in the area. Replace the engine oil and fuel referring to recommended oils at page 2-16. Fill the anti-freeze solution to the coolant as required. (1) Check if all the levers are on the neutral position. (2) Inject ether by pressing preheat switch. (3) Start the engine by turning the starting switch to the START position after inject ether. If the engine does not start, allow the starter to cool for about 2 minutes before attempting to start the engine again. (4) Release the starting switch immediately after starting engine.

OFF

(5) The operation for the warming up machine is automatic.

29074OP03A

3) STARTING ENGINE IN COLD WEATHER(TIER II) Sound horn to warn surroundings after checking if there are obstacles in the area. Replace the engine oil and fuel referring to recommended oils at page 2-16. Fill the anti-freeze solution to the coolant as required. (1) Check if all the levers are in the neutral position. (2) Turn the starting switch to ON position, and wait the preheat pilot lamp OFF. (3) Start the engine by turning the starting switch to the START position after the preheat pilot lamp OFF If necessary use the preheat switch. If the engine does not start, allow the starter to cool for about 2 minutes before attempting to start the engine again. (4) Release the starting switch immediately after starting engine. (5) The operation for the warming up machine is automatic.

4-4

OFF 21074OP03A

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

4) INSPECTION AFTER ENGINE START Inspect and confirm the following after engine starts. (1) Is the level gauge of hydraulic oil tank in the normal level? (2) Are there leakages of oil or water? (3) Are all the warning lamps OFF(1-7)? 1

(4) Is the indicator of water temperature gauge(8) and hydraulic temperature gauge(9) in the green zone? (5) Is the engine sound and the color of exhaust gas normal? (6) Are the sound and vibration normal?

9 8 7

2 3 4

Do not increase engine speed quickly after starting, it can damage engine or turbocharger. If there are problems in the control panel, stop the engine immediately and correct problem as required. 29074OP03B

5) WARMING-UP OPERATION The most suitable temperature for the hydraulic oil is about 50 C(122 F). It can cause serious trouble in the hydraulic system by sudden operation when the hydraulic oil temperature is below 25 C(77 F). Then temperature must be raised to at least 25 C(77 F) before starting work.

(1) Run the engine at low idling for 5 minutes. (2) Speed up the idling and run the engine at midrange speed. (3) Operate bucket lever for 5 minutes. Do not operate anything except bucket lever. (4) Run the engine at the high speed and operate the bucket lever and arm lever for 5-10 minutes. Operate only the bucket lever and arm lever. (5) This warming-up operation will be completed by operation of all cylinders several times, and operation of swing and traveling. Increase the warming-up operation during winter.

4-5

21074OP05

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

6) TO STOP THE ENGINE If the engine is abruptly stopped before it has cooled down, engine life may be greatly shortened. Consequently, do not abruptly stop the engine apart from an emergency. In particularly if the engine has overheated, do not abruptly stop it but run it at medium speed to allow it to cool gradually, then stop it.

Low idling for 5 minutes

Down the bucket on the ground then put all (1) the levers in the neutral position. Run the engine at low idling speed for about 5 (2) minutes. Return the key of starting switch to the OFF (3) position. Remove the key to prevent other people (4) using the machine and LOCK safety lever. Lock the cab door.

START ON

(5) 21074OP04

4-6

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

4. MODE SELECTION SYSTEM 1) STRUCTURE OF CAPO SYSTEM CAPO, Computer Aided Power Optimization system, is the name of mode selection system developed by Hyundai. (1) Work mode 3 work modes can be selected for the optimal work speed of the machine operation. Heavy duty work mode The boom priority solenoid is activated to make the boom operation speed faster. General work mode When key switch is turned ON, this mode is selected automatically and swing operation speed is faster than heavy duty work mode. Breaker operation mode It sets the pump flow to the optimal operation of breaker by activating the max flow cut-off solenoid. (2) Power mode Power mode designed for various work loads maintains high performance and reduces fuel consumption. H mode : High power S mode : Standard power (3) User mode M : Maximam power U : You can change the engine and pump power and memorize it for your preference

18074OP03C

1 2 3 4 5 6

Work mode Power mode User mode Auto decel mode Travel mode Monitoring display

How to modulate the memory set Each memory mode has a initial set which are mid-range of max engine speed, auto decel rpm, and EPPR valve input current. When you select U, cluster LCD displays.

21074OP03G

4-7

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

To change the engine high idle speed, press the USER mode switch and SELECT switch at the same time and then ACCEL blinks at 0.5 seconds interval. - By pressing or switch, will increase or decrease. To change DECEL rpm, press the USER mode switch and SELECT switch once more and then DECEL blinks at 0.5 seconds interval. - By pressing or switch, will increase or decrease. To change EPPR current, press the USER mode switch and SELECT switch once more and then EPPR blinks at 0.5 seconds interval. - By pressing or switch, will increase or decrease. LCD segment vs parameter setting Segment ( )

ACCEL (rpm)

DECEL (rpm)

EPPR (mA)

High idle-900

Low idle 800 *700

150

High idle-800 1050

*800

200

High idle-700 1100

*900

250

High idle-600 1150

*1000

300

High idle-500

Decel rpm 1200 *1100

350

High idle-400 1250

*1200

400

High idle-300 1300

*1250

450

High idle-200 1350

*1300

500

High idle-100 1400

*1350

550

*1400

600

High idle

1500

* : TIER II only To memorize the final setting, press the USER mode switch and SELECT switch one more time. (4) Auto decel mode Engine quick deceleration. (5) Travel mode : Low speed traveling. : High speed traveling.

4-8

18074OP03H

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

(6) Monitoring system Information of machine performance as monitored by the CPU controller can be displayed on the monitoring display. Refer to 4-11 page for details. (7) Self diagnostic system The CPU controller diagnoses problems in the CAPO system caused by electric parts' malfunction and by open or short circuit, which are displayed on the monitoring display as error codes. (8) Anti-restart system The system protects the starter from inadvertent restarting after the engine is already operational. 2) HOW TO OPERATE MODE SELECTION SYSTEM (1) When start key is turned ON When start key is turned ON, all illumination lamps are ON and all lamps are OFF automatically after 5 seconds. But a battery charging warning lamp and an engine oil pressure warning lamp keep turned ON until engine starting. After lamp check CL : 1.5 , the version of cluster program, is displayed on Monitoring display for 2 seconds. After the version of program is displayed, the cluster returns to default. Exactly engine rpm, battery charging warning lamp and engine oil pressure warning lamp are turned ON and S mode, auto decel, low travel speed(Turtle mark) are displayed. In default condition self-diagnostic function including trouble detecting of electric system can be carried out. Refer to 4-11 page for details.

4-9

18074OP03D

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

(2) After engine start When the engine is started, three lamps are ON as below. Mode

Status

Work mode

Power mode Travel mode

S Low(

)

Auto decel mode

ON ON

In this condition, tachometer indicates low idle, 800 100rpm/700 100rpm(TIER II). If coolant temperature is below 30 C, after 10 seconds the engine speed increases to 1200 100rpm/1000 100rpm(TIER II) automatically to warm up the machine. After 2-3 minutes, you can select any mode depending on job requirement. Self-diagnostic function can be carried out the same as start key is ON. Refer to 4-11 page for details.

29074OP03K

3) SELECTION OF POWER MODE (1) S mode When the accel dial is at setting 10 and auto decel mode is cancelled and S mode is selected. Engine rpm 1950 *1750

50 50

Effect Same power as non mode type machine.

* : TIER II only When the accel dial is located below 9 the engine speed decreases about 50~100rpm per dial set.

21073CD23A

(2) H mode When the accel dial is at setting 10 and auto decel mode is cancelled and H mode is selected. Engine rpm 2090

*1850

Effect Approximately 110% of power and speed available than non mode type machine or S mode.

* : TIER II only When the accel dial is located below 9 the engine speed decreases about 50~100rpm per dial set.

4-10

21073CD23B

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

(3) M mode When the accel dial is at setting 10 and auto decel mode is cancelled and H mode is selected. Engine rpm

1950

Effect Approximately 130% of power and speed available than non mode type machine or S mode.

When the accel dial is located below 9 the engine speed decreases about 50~100rpm per dial set.

4-11

17W73CD21

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

4) MONITORING DISPLAY Information of machine performance as monitored by the CPU controller can be displayed on the cluster when the operator selects a display mode by touching SELECT switch alone or with BUZZER STOP switch on the cluster as below. Display group

How to select display mode Group selection

Way 1 Key switch ON or START Group 0 (Default)

Initial

Engine rpm

Touch SELECT 1 time

Time

Touch SELECT 2 times

Power shift pressure (EPPR valve)

Touch SELECT 3 times Way 2 Touch AUTO DECEL *Touch SELECT 3 times switch while pressing BUZZER STOP at Touch SELECT Option 4 times group 1~4. (Only when Touch SELECT a pressure 5 times sensor is Touch SELECT installed) 6 times

CPU model & version CPU model & version Front pump pressure Rear pump pressure Pilot pressure

Default

Battery voltage(V)

Touch SELECT 1 time

Potentiometer voltage(V)

Touch SELECT switch once while pressing Touch SELECT 2 times

Group 1 (Volt, temp, BUZZER STOP. EPPR press, In this group SELECT Touch SELECT 3 times version) LED ON Touch SELECT 4 times *Touch SELECT 5 times

Group 2 (Error code)

Name

Display mode selection

Touch SELECT switch Default twice while pressing Touch SELECT 1 time BUZZER STOP. In this group BUZZER Press down( ) & STOP LED blinks SELECT at the same time

Accel dial voltage(V) Hydraulic oil temperature( C) Coolant temperature( C) Ambient pressure(KPA) Current error Recorded error (Only key switch ON) Recorded error deletion (Only key switch ON)

Default

Pump prolix switch

Touch SELECT 1 time

Auto decel pressure switch

Touch SELECT switch Touch SELECT 2 times 3 times while pressing BUZZER STOP. Group 3 Touch SELECT 3 times (Switch input) In this group SELECT LED blinks at 0.5sec Touch SELECT 4 times interval

Power boost switch Travel oil pressure switch One touch decel switch

Touch SELECT 5 times

Travel alarm switch

Touch SELECT 6 times

Preheat switch

* : TIER II only 4-12

Display on the cluster

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

Display group

How to select display mode Group selection

Touch SELECT switch 4 times while pressing Group 4 (Output)

BUZZER STOP. In this group SELECT

Display mode selection

Name

Default

Hourmeter

Touch SELECT 1 time

Neutral relay (Anti-restart relay)

Touch SELECT 2 times

Travel speed solenoid

Touch SELECT 3 times

Power boost solenoid (2-stage relief solenoid)

LED blinks at 1sec Touch SELECT 4 times interval Touch SELECT 5 times

Boom priority solenoid Travel alarm

Touch SELECT 6 times

Max flow cut off solenoid

Touch SELECT 7 times

Preheat relay

By touching SELECT switch once while pressing BUZZER STOP, display group shifts. Example : Group 0 1 2 3 4 0

4-13

Display on the cluster

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

5. OPERATION OF WORKING DEVICE Confirm the operation of control lever and working device. 1) Left control lever controls arm and swing. 2) Right control lever controls boom and bucket.

76 5 8

3) When you release the control lever, control lever returns to neutral position automatically.

32 1 4

When operating swing, consider the swing distance by inertia.

21074OP06

Left control lever 1 Arm roll-out 2 Arm roll-in 3 Swing right 4 Swing left

4 2

21074OP07

Right control lever 5 Boom lower 6 Boom raise 7 Bucket roll-out 8 Bucket roll-in

7 5 8

21074OP08

4-14

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

6. TRAVELING OF THE MACHINE 1) BASIC OPERATION (1) Traveling position It is the position which the traveling motor is in the rear and the working device is forward. Be careful as the traveling direction will be reversed when the whole machine is swinged 180 degree (2) Traveling operation It is possible to travel by either travel lever or pedal. Do not travel continuously for a long time. Reduce the engine speed and travel at a low speed when traveling on uneven ground.

21074OP09

(3) Forward and backward traveling When the left and right travel lever or pedal are pushed at the same time, the machine will travel forward or backward. The speed can be controlled by the operation stroke of lever or pedal and change of direction will be controlled by difference of the left and right stroke. 21074OP10

(4) Pivot turning Operating only one side of lever or pedal make the change of direction possible by moving only one track.

21074OP11

(5) Counter rotation It is to change the direction at the original place by moving the right and left track. Both side of lever or pedal are operated to the other way at the same time.

21074OP12

4-15

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

2) TRAVELING ON A SLOPE (1) Make sure that the travel lever is properly maneuvered by confirming the travel motor is in the right location. (2) Lower the bucket 20 to 30cm(1ft) to the ground so that it can be used as a brake in an emergency. (3) If the machine starts to slide or loses stability, lower the bucket immediately and brake the machine.

20~

30c

m(1

ft)

Travel motor

(4) When parking on a slope, use the bucket as a brake and place blocks behind the tracks to prevent sliding. Machine cannot travel effectively on a slope when the oil temperature is low. Do the warming-up operation when it is going to travel on a slope. Be careful when working on slopes. It may cause the machine to lose its balance and turn over. Be sure to keep the travel speed switch on the LOW(Turtle mark) while traveling on a slope.

Travel motor

20~30cm(1ft)

21074OP13

3) TRAVELING ON SOFT GROUND If possible, avoid to operate on soft ground. (1) Move forward as far as machine can move. (2) Take care not to go beyond the depth where towing is impossible on soft ground. (3) When driving becomes impossible, lower bucket and use boom and arm to pull the machine. Operate boom, arm, and travel lever at the same time to avoid the machine sinking.

4-16

90 ~ 110

21074OP14

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

4) TOWING THE MACHINE Tow the machine as follows when it can not move on it's own.

Correct

(1) Tow the machine by other machine after hook the wire rope to the frame as shown in picture at right. (2) Hook the wire rope to the frame and put a support under each part of wire rope to prevent damage. â&#x20AC;ť Never tow the machine using only the tie hole, because this may break. Make sure no personnel are standing close to the tow rope.

Wire rope

Incorrect

Tie hole

Wire rope

21074OP14A

4-17

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

7. EFFICIENT WORKING METHOD 1) Do the digging work by arm. Use the pulling force of arm for digging and use together with the digging force of the bucket if necessary.

21074OP15

2) When lowering and raising the boom operate softly for the beginning and the end. In particularly, sudden stops while lowering the boom may cause damage to the machine.

Operate softy for the begining and the end

21074OP16

3) The digging resistance and wearing of tooth can be reduced by putting the end of bucket tooth to the digging direction.

13034OP39

4) Set the tracks parallel to the line of the ditch to be excavated when digging ditch. Do not swing while digging.

Parallel 21074OP17

4-18

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

5) Dig slowly with keeping the angle of boom and arm, 90-110 degree when maximum digging force is required. 90~110

21074OP18

6) Operate leaving a small safety margin of cylinder stroke to prevent damage of cylinder when working with the machine.

Margin

21074OP19

7) Keep the bucket to the dumping position and the arm horizontal when dumping the soil from the bucket. Operate bucket lever 2 or 3 times when hard to dump. Do not use the impact of bucket tooth when dumping. 21074OP20

8) Operate stop of swing considering the swing slip distance is created by inertia after neutralizing the swing lever. Inertia

Swing stop 21074OP21

4-19

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

9) Do not use the dropping force of the work equipment for digging. The machine can be damaged by the impact.

Incorrect

21074OP22

10) Do not use the bucket to crack hard objects like concrete or rocks. This may break a tooth or pin, or bend boom.

Incorrect

21074OP23

11) NEVER CARRY OUT EXCESSIVE OPERATIONS Operation exceeding machine performance may result in accident or failure. Carry out lifting operation within specified load limit. Never carry out operations which may damage the machine such as overload or over-impactload. Never travel while carrying a load. In case you need installing over load warning device for object handling procedure, please contact Hyundai distributor.

Incorrect

29074OP35

4-20

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

12) BUCKET WITH HOOK When carrying out lifting work, the special lifting hook is necessary. The following operations are prohibited. Lifting loads with a wire rope fitted around the bucket teeth. Lifting loads with the wire rope wrapped directly around the boom or arm.

Hook

When performing lifting operation, securely hook the wire rope onto the special lifting hook. When performing lifting operation, never raise or lower a person. Due to the possible danger of the load falling or of collision with the load, no persons shall be allowed in the working area. Before performing lifting operation, designate an operation supervisor. Always execute operation according to his instructions. Execute operating methods and procedures under his direction. Select a person responsible for signaling. Operate only on signals given by such person. Never leave the operator's seat while lifting a load.

4-21

21074OP24

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

8. OPERATION IN THE SPECIAL WORK SITES 1) OPERATION THE MACHINE IN A COLD WEATHER (1) Use proper engine oil and fuel for the weather. (2) Fill the required amount of antifreeze in the coolant.

(3) Refer to the starting engine in cold weather. Start the engine and extend the warming up operation. (4) Be sure to open the heater cock when using the heater. (5) Always keep the battery completely charged. Discharged batterys will freeze more easily than fully charged. (6) Clean the machine and park on the wood plates. 2) OPERATION IN SANDY OR DUSTY WORK SITES (1) Inspect air cleaner element frequently. Clean or replace element more frequently, if warning lamp comes ON and buzzer sounds simultaneously, regardless of inspection period. Replace the inner and outer element after 6 times of cleaning. (2) Inspect radiator frequently, and keep cooling fins clean. (3) Prevent sand or dust from getting into fuel tank and hydraulic tank during refilling. (4) Prevent sand or dust from penetrating into hydraulic circuit by tightly closing breather cap of hydraulic oil tank. Replace hydraulic oil filter frequently. (5) Keep all lubricated part, such as pins and bushings, clean at all times. (6) If the air conditioner and heater filters clogged, the heating or cooling capacity will drop. Clean or replace the filter element more frequently.

4-22

21074OP29

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

3) SEA SHORE OPERATION (1) Prevent ingress of salt by securely tightening plugs, cocks and bolts of each part. (2) Wash machine after operation to remove salt residue. Pay special attention to electrical parts and hydraulic cylinders to prevent corrosion. (3) Inspection and lubrication must be carried out more frequently. Supply sufficient grease to replace all old grease in bearings which have been submerged in water for a long time.

4-23

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

9. NORMAL OPERATION OF EXCAVATOR Followings may occur during operation due to the nature of a hydraulic excavator. 1) When rolling in the arm, the roll-in movement stop momentary at point X in the picture shown, then recovers speed again after passing point X. The reason for this phenomenon is that movement by the arm weight is faster than the speed of oil flow into the cylinder. 2) When lowering the boom, one may hear continuous sound. This is caused by oil flow in the valve.

3) Overloaded movement will produce sound caused by the relief valves, which are for the protection of the hydraulic systems. 4) When the machine is started swing or stopped, a noise near the swing motor may be heard. The noise is generated when the brake valve relieves.

4-24

21074OP25

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

10. ATTACHMENT LOWERING(When engine is stopped) 1) On machines equipped with an accumulator, for a short time(within 2 minutes) after the engine is stopped, the attachment will lower under its own weight when the attachment control lever is shifted to LOWER. That is happen only starting switch ON position and safety lever UNLOCK position. After the engine is stopped, set the safety lever to the LOCK position. Be sure no one is under or near the attachment before lowering the boom. 2) The accumulator is filled with high-pressure nitrogen gas, and it is extremely dangerous if it is handled in the wrong way. Always observe the following precautions. Never make any hole in the accumulator expose it to flame or fire. Do not weld anything to the accumulator. When carrying out disassembly or maintenance of the accumulator, or when disposing of the accumulator, it is necessary to release the gas from the accumulator. A special air bleed valve is necessary for this operation, so please contact your Hyundai distributor.

Accumulator

29074OP25

4-25

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

11. STORAGE Maintain the machine taking care of following to prevent the deterioration of machine when storing the machine for a long time, over 1 month. 1) CLEANING THE MACHINE Clean the machine. Check and adjust tracks. Grease each lubrication part.

4 3

2) LUBRICATION POSITION OF EACH PART Change all oil. Be particularly careful when you reuse the machine. As oil can be diluted during storage. Apply an anticorrosive lubricant on the exposed part of piston rod of cylinder and in places where the machine rusts easily.

5 1 2 3 4 5

Lubricating manifold(5EA) Boom cylinder pin(2EA) Boom and arm connection pin(1EA) Arm cylinder pin(rod side, 1EA) Arm and bucket(6EA) 21074OP26

3) MASTER SWITCH Turn OFF the master switch mounted electric box and store the machine. 4) Be sure to mix anticorrosive antifreezing solution in the radiator.

Electric box

Master switch OFF

29074OP30

5) PREVENTION OF DUST AND MOISTURE Keep machine dry. Store the machine setting wood on the ground. Cover exposed part of piston rod of cylinder. Lower the bucket to the ground and set a support under track.

21074OP27

4-26

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

6) DURING STORAGE Start engine and move the machine and work equipment once a month and apply lubrication to each part.

Lubricating operation once a month

Check the level of engine oil and coolant and fill if required when starting engine. Clean the anticorrosive on the piston rod of cylinder. Operate the machine such as traveling, swing and work equipment operation to make sure enough lubrication of all functional components.

21074OP30

4-27

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

12. RCV LEVER OPERATING PATTERN 90 (Lever only)

Nut(20) Mounting bolt(21)

Terminal block

H F D A

Whenever a change is made to the machine control pattern also exchange the pattern label in the cab to match the new pattern.

G E B

29074OP28

Operation Pattern

Left

Control function

Right

ISO Type Left

Right Hyundai A Type Left

Right

B Type Left

Right

C Type Left

Right

4-28

Arm out Arm in Swing right Swing left Boom lower Boom raise Bucket out Bucket in Boom lower Boom raise Swing right Swing left Arm out Arm in Bucket out Bucket in Boom lower Boom raise Bucket in Bucket out Arm out Arm in Swing right Swing left

Hose connection(Port) Change of MCV port RCV lever From To D E A B J H F G D J E H A B D J E H F G J D H E G A F B D J E H A F B G

Loosen the RCV lever mounting bolt(21) and rotates lever assy 90 counterclockwise; then install. To put lever in correct position, disassemble nut(20) and rotates only lever 90 clockwise.

Same as ISO type

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

13. SWITCHING HYDRAULIC ATTACHMENT CIRCUIT 1) The combined hydraulic attachment circuit is capable of providing single action or double action. 2) The position of 3 way valve selects the single action hydraulic attachment circuit or the double action hydraulic attachment circuit.

3) Before you change the flow mode of hydraulic attachment circuit, place the machine in the servicing position as shown. Stop the engine.

29074OP04

4) Use the manual lever to turn the 3 way valve. Make sure that you fully turn the valve until the valve stops. (1) One way flow(Hydraulic breaker) Position the manual lever parallel to the piping ( ). (2) Two way flow(Clamshell or shear) Position the manual lever perpendicular to the piping( ).

4-29

FRONT

29074OP36

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

TRANSPORTATION 1. PREPARATION FOR TRANSPORTATION 1) When transporting the machine, observe the various road rules, road transportation vehicle laws and vehicle limit ordinances, etc.

Overall

2) Select proper trailer after confirming the weight and dimension from the chapter 2, specification. 3) Check the whole route such as the road width, the height of bridge and limit of weight and etc., which will be passed.

Overall

4) Get the permission from the related authority if necessary. Overall

5) Prepare suitable capacity of trailer to support the machine.

21075TA01

6) Prepare gangplank for safe loading referring to the below table and illustration. A

1.0

3.65 ~ 3.85

1.1

4.00 ~ 4.25

1.2

4.35 ~ 4.60

1.3

4.75 ~ 5.00

1.4

5.10 ~ 5.40

1.5

5.50 ~ 5.75

Loading plate of trailer A Block

B Gan gpla nk

15 ~ 16ă&#x20AC;&#x201A;

13035TA02

5-1

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

2. DIMENSION AND WEIGHT 1) R290LC-7

Mark

Description

Unit

Specification

Length

mm(ft-in)

5590(18' 4")

Height

mm(ft-in)

3010( 9' 11")

Width

mm(ft-in)

3200(10' 6")

Weight

kg(lb)

23850(52580)

(1) BASE MACHINE

※ With 600mm(24") triple grouser shoes and 5200kg (11460lb) counterweight.

21075TA02

Mark

Description

Unit

Specification

Length

mm(ft-in)

6470(21' 3")

Height

mm(ft-in)

1730( 5' 8")

Width

mm(ft-in)

790( 2' 7")

Weight

kg(lb)

(2) BOOM ASSEMBLY

2620(5780)

※ 6.25m(20' 6") boom with arm cylinder(Included piping and pins). 13035TA03

Mark

Description

Unit

Specification

Length

mm(ft-in)

4190(13' 9")

Height

mm(ft-in)

950( 3' 1")

Width

mm(ft-in)

360( 1' 2")

Weight

kg(lb)

(3) ARM ASSEMBLY

1450(3200)

※ 3.05m(10' 0") arm with bucket cylinder(Included linkage and pins). 13035TA04

Mark

Description

Unit

Specification

Length

mm(ft-in)

1780( 5' 10")

Height

mm(ft-in)

1070( 3' 6")

Width

mm(ft-in)

1410( 4' 8")

Weight

kg(lb)

960(2120)

※ 1.27m3(1.66yd3) PCSA heaped bucket(Included tooth and side cutters).

5-2

(4) BUCKET ASSEMBLY

13035TA05

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

Mark

Description

Unit

Specification

Length

mm(ft-in)

2240( 7' 4")

Height

mm(ft-in)

260( 0' 10")

Width

mm(ft-in)

390( 1' 3")

Weight(2EA)

kg(lb)

580(1280)

(5) BOOM CYLINDER

â&#x20AC;» Included piping. 13035TA06

Mark

Description

Unit

Specification

Length

mm(ft-in)

1962( 6' 4")

Height

mm(ft-in)

1676( 5' 5")

Width

mm(ft-in)

1288( 4' 2")

Weight

kg(lb)

310(680)

(6) CAB ASSEMBLY

W 21075TA03

Mark

Description

Unit

Specification

Length

mm(ft-in)

2980( 9' 9")

Height

mm(ft-in)

1050( 3' 5")

Width

mm(ft-in)

590( 1' 11")

Weight

kg(lb)

5200(11460)

(7) COUNTERWEIGHT

21075TA04

5-3

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

2) R290NLC-7

Mark

Description

Unit

Specification

Length

mm(ft-in)

5590(18' 4")

Height

mm(ft-in)

3010( 9' 11")

Width

mm(ft-in)

2990( 9' 10")

Weight

kg(lb)

23650(52140)

(1) BASE MACHINE

※ With 600mm(24") triple grouser shoes and 5200kg (11460lb) counterweight.

21075TA02

3) R290LC-7 LONG REACH

Mark

Description

Unit

Specification

Length

mm(ft-in)

5590(18' 4")

Height

mm(ft-in)

3010( 9' 11")

Width

mm(ft-in)

3400(11' 2")

Weight

kg(lb)

27340(60350)

(1) BASE MACHINE

※ With 800mm(32") triple grouser shoes and 6200kg (13670lb) counterweight.

21075TA02

Mark

Description

Unit

Specification

Length

mm(ft-in)

10410(34' 2")

Height

mm(ft-in)

1675( 5' 6")

Width

mm(ft-in)

900( 3' 1")

Weight

kg(lb)

(2) BOOM ASSEMBLY

3320(7320)

※ 10.2m(33' 6") boom with arm cylinder(Included piping and pins). 29075TA01

Mark

Description

Unit

Specification

Length

mm(ft-in)

9010(29' 7")

Height

mm(ft-in)

870( 2' 10")

Width

mm(ft-in)

480( 1' 7")

Weight

kg(lb)

(3) ARM ASSEMBLY

1590(3510)

※ 7.85m(25' 9") arm with bucket cylinder(Included linkage and pins). 29075TA02

5-4

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

Mark

Description

Unit

Specification

Length

mm(ft-in)

1400( 4' 7")

Height

mm(ft-in)

820( 2' 8")

Width

mm(ft-in)

1035( 3' 5")

Weight

kg(lb)

440(970)

(4) BUCKET ASSEMBLY

※ 0.52m (0.68yd ) PCSA heaped bucket(Included tooth and side cutters). 3

13035TA05

Mark

Description

Unit

Specification

Length

mm(ft-in)

2980( 9' 9")

Height

mm(ft-in)

1050( 3' 5")

Width

mm(ft-in)

590( 1' 11")

Weight

kg(lb)

6200(13670)

(5) COUNTERWEIGHT

21075TA04

4) R290LC-7 HIGH WALKER

Mark

Description

Unit

Specification

Length

mm(ft-in)

5595(18' 4")

Height

mm(ft-in)

3380(11' 1")

Width

mm(ft-in)

3470(11' 5")

Weight

kg(lb)

26690(58840)

※ With 600mm(24") triple grouser shoes and 5200kg (11460lb) counterweight.

5-5

(1) BASE MACHINE

21075TA02

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

3. LOADING THE MACHINE 1) Load and unload the machine on a flat ground. 2) Use the gangplank with sufficient length, width, thickness and gradient. 3) Place the swing lock lever to the LOCK position before fixing the machine at the bed of trailer and confirm if the machine parallels the bed of trailer. Keep the travel motor in the rear when loading and in the front when unloading. 21075TA05

4) Do the following after loading the machine to the trailer. (1) Stop loading when the machine is located horizontally with the rear wheel of trailer.

21075TA06

(2) Place the swing lock lever to the LOCK position after the swing the machine 180 degree.

21075TA07

5-6

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

(3) Lower the working equipment gently after the location is determined. â&#x20AC;ť Place rectangular timber under the bucket cylinder to prevent the damage of it during transportation. Be sure to keep the travel speed switch on the LOW(Turtle mark) while loading and unloading the machine. Avoid using the working equipment for loading and unloading since it will be very dangerous. Do not operate any other device when loading. Be careful on the boundary place of loading plate or trailer as the balance of machine will abruptly be changed on the point.

21075TA08

The machine with long reach attachments should be moved or transmitted with boom and arm fixed using stay. Stay

29075TA03

5) Fix method of stay bracket.

5~7mm

(1) Extend arm cylinder to maximum. (2) Mark on the rod of 5~7mm distance from tube end. (3) Retract the arm cylinder to the mark. (4) Adjust the stay bracket and than fix the stay to the proper location.

5~7mm

Stay

Stay bracket 29075TA04

5-7

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

4. FIXING THE MACHINE 1) Lower down the working device on the loading plate of trailer.

Starting switch

2) Keep the safety lever on the LOCK position. 3) Turn OFF all the switches and remove the key.

Safety lever 21075TA09

4) Secure all locks. Tool box & fuel tank Engine hood

Cab

Side cover 21075TA10

5) Place timber underneath of the track and fix firmly with wire rope to prevent the machine from moving forward, backward, right or left.

Chain

21075TA11

5-8

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

5. LOADING AND UNLOADING BY CRANE 1) Check the weight, length, width and height of the machine referring to the chapter 2, specification when you are going to hoist the machine.

Wire rope Stay

2) Use long wire rope and stay to keep the distance with the machine as it should avoid touching with the machine. 0.5~1.0m

3) Put a rubber plate contact with wire rope and machine to prevent damage.

Between track roller Between track roller and idler No.1 and No.2

4) Place crane on the proper place. 5) Install the wire rope and stay like the illustration. Make sure wire rope is proper size. Place the swing lock lever and safety lever to LOCK position to prevent the machine moving when hoisting the machine. The wrong hoisting method or installation of wire rope can cause damage to the machine. Do not load abruptly. Keep area clear of personnel.

5-9

Wire rope stay

REAR VIEW 21075TA12

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

MAINTENANCE 1. INSTRUCTION 1) INTERVAL OF MAINTENANCE (1) You may inspect and service the machine by the period as described at page 6-11 based on service meter at cluster support. (2) Shorten the interval of inspect and service depending on site condition.(Such as dusty area, quarry, sea shore and etc.) (3) Practice the entire related details at the same time when the service interval is doubled. For example, in case of 100hours, carry out all the maintenanceă&#x20AC;&#x152;Each 100hours, each 50 hours and daily serviceă&#x20AC;?at the same time.

Service meter

21076MA01

2) PRECAUTION (1) Start to maintenance after you have the full knowledge of machine. (2) The monitor installed on this machine does not entirely guarantee the condition of the machine. Daily inspection should be performed according to clause 4, maintenance check list. (3) Engine and hydraulic components have been preset in the factory. Do not allow unauthorized personnel to reset them. (4) Ask to your local dealer or Hyundai for the maintenance advice if unknown. (5) Drain the used oil and coolant in a container and handle according to the method of handling for industrial waste to meet with regulations of each province or country.

6-1

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

3) PROPER MAINTENANCE (1) Preplace and repair of parts It is required to replace the wearable and consumable parts such as bucket tooth, side cutter, filter and etc., regularly. Replace damaged or worn parts at proper time to keep the performance of machine. (2) Use genuine parts. (3) Use the recommended oil. (4) Remove the dust or water around the inlet of oil tank before supplying oil. (5) Drain oil when the temperature of oil is warm. (6) Do not repair anything while operating the engine. Stop the engine when you fill the oil. (7) Relieve hydraulic system of the pressure before repairing the hydraulic system. (8) Confirm if the cluster is in the normal condition after completion of service. (9) For more detail information of maintenance, please contact local Hyundai dealer. â&#x20AC;ť Be sure to start the maintenance after fully understand the chapter 1, safety hints.

6-2

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

4) RELIEVING THE PRESSURE IN THE HYDRAULIC SYSTEM â&#x20AC;ť Spouting of oil can cause the accident when loosening the cap or hose right after the operating of machine as the machine or oil is on the high pressure on the condition. Be sure to relieve the pressure in the system before repairing hydraulic system. Place machine in parking position, and stop (1) the engine.

21076MA02

(2) Set the safety lever completely in the release position, operate the control levers and pedals fully to the front, rear, left and right, to release the pressure in the hydraulic circuit. â&#x20AC;ť This does not completely release the pressure, so when serving hydraulic component, loosen the connections slowly and do not stand in the direction where the oil spurt out.

Lever

Pedal

21076MA03

(3) Loosen the cap and relieve the pressure in the tank by pushing the top of the air breather.

Cap Pushing

Air breather

29076MI04

6-3

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

5) PRECAUTION WHEN INSTALLING HYDRAULIC HOSES OR PIPES (1) Be particularly careful that the joint of hose, pipe and functioning item are not damaged. Avoid contamination. (2) Assemble after cleaning the hose, pipe and joint of functioning item. (3) Use genuine parts. (4) Do not assemble the hose in the condition of twisted or sharp radius. (5) Keep the specified tighten torque.

6-4

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

6) PERIODICAL REPLACEMENT OF SAFETY PARTS (1) It is desirable to do periodic maintenance the machine for using the machine safely for a long time. However, recommend to replace regularly the parts related safety not only safety but maintain satisfied performance. (2) These parts can cause the disaster of life and material as the quality changes by passing time and it is worn, diluted, and gets fatigued by using repeatedly. These are the parts which the operator can not judge the remained lifetime of them by visual inspection. (3) Repair or replace if an abnormality of these parts is found even before the recommended replacement interval. Periodical replacement of safety parts Fuel hose(tank-engine) Engine

Heater hose (heater-engine)

Interval Every 2 years

Pump suction hose Main circuit Hydraulic system

Pump delivery hose

Every 2 years

Swing hose Boom cylinder line hose Working Every Arm cylinder line hose device 2 years Bucket cylinder line hose

1. Replace O-ring and gasket at the same time â&#x20AC;ť1 when replacing the hose. 2. Replace clamp at the same time if the hose clamp is cracked when checking and replacing the hose.

6-5

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

2. TIGHTENING TORQUE Use following table for unspecified torque. 1) BOLT AND NUT (1) Coarse thread Bolt size

10T

kgf·m

lbf·ft

kgf·m

lbf·ft

M 6×1.0

0.85 ~ 1.25

6.15 ~ 9.04

1.14 ~ 1.74

8.2 ~ 12.6

M 8×1.25

2.0 ~ 3.0

14.5 ~ 21.7

2.7 ~ 4.1

19.5 ~ 29.7

M10×1.5

4.0 ~ 6.0

28.9 ~ 43.4

5.5 ~ 8.3

39.8 ~ 60.0

M12×1.75

7.4 ~ 11.2

53.5 ~ 81.0

9.8 ~ 15.8

70.9 ~ 114

M14×2.0

12.2 ~ 16.6

88.2 ~ 120

16.7 ~ 22.5

121 ~ 163

M16×2.0

18.6 ~ 25.2

135 ~ 182

25.2 ~ 34.2

182 ~ 247

M18×2.0

25.8 ~ 35.0

187 ~ 253

35.1 ~ 47.5

254 ~ 344

M20×2.5

36.2 ~ 49.0

262 ~ 354

49.2 ~ 66.6

356 ~ 482

M22×2.5

48.3 ~ 63.3

349 ~ 458

65.8 ~ 98.0

476 ~ 709

M24×3.0

62.5 ~ 84.5

452 ~ 611

85.0 ~ 115

615 ~ 832

M30×3.0

124 ~ 168

898 ~ 1214

169 ~ 229

1223 ~ 1656

M36×4.0

174 ~ 236

1261 ~ 1704

250 ~ 310

1808 ~ 2242

(2) Fine thread Bolt size

10T

kgf·m

lbf·ft

kgf·m

lbf·ft

M 8×1.0

2.2 ~ 3.4

15.9 ~ 24.6

3.0 ~ 4.4

21.7 ~ 31.8

M10×1.2

4.5 ~ 6.7

32.5 ~ 48.5

5.9 ~ 8.9

42.7 ~ 64.4

M12×1.25

7.8 ~ 11.6

56.4 ~ 83.9

10.6 ~ 16.0

76.7 ~ 116

M14×1.5

13.3 ~ 18.1

96.2 ~ 131

17.9 ~ 24.1

130 ~ 174

M16×1.5

19.9 ~ 26.9

144 ~ 195

26.6 ~ 36.0

192 ~ 260

M18×1.5

28.6 ~ 43.6

207 ~ 315

38.4 ~ 52.0

278 ~ 376

M20×1.5

40.0 ~ 54.0

289 ~ 391

53.4 ~ 72.2

386 ~ 522

M22×1.5

52.7 ~ 71.3

381 ~ 516

70.7 ~ 95.7

511 ~ 692

M24×2.0

67.9 ~ 91.9

491 ~ 665

90.9 ~ 123

658 ~ 890

M30×2.0

137 ~ 185

990 ~ 1339

182 ~ 248

1314 ~ 1796

M36×3.0

192 ~ 260

1390 ~ 1880

262 ~ 354

1894 ~ 2562

6-6

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

2) PIPE AND HOSE Thread size

Width across flat(mm)

kgf路m

lbf路ft

1/4"

21.7

3/8"

28.9

1/2"

36.2

3/4"

86.8

101

Thread size

Width across flat(mm)

kgf路m

lbf路ft

1/4"

28.9

3/8"

36.2

1/2"

43.4

3/4"

94.0

109

3) FITTING

6-7

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

4) TIGHTENING TORQUE OF MAJOR COMPONENT No.

Descriptions

Bolt size

Torque kgfÂm

lbfÂft

Engine mounting bolt, nut

M24 Ý 3.0

90 Ü 7.0

651 Ü 51

Engine mounting bolt, nut(FR.TIER II)

M20 Ý 2.5

55 Ü 3.5

398 Ü 25

Engine mounting bolt, nut(RR.TIER II)

M24 Ý 3.0

90 Ü 7.0

651 Ü 51

Radiator mounting bolt

M16 Ý 2.0

25.7 Ü 4.0

186 Ü 29

Coupling mounting socket bolt

M20 Ý 2.5

44 Ü 4.5

318 Ü 33

Main pump housing mounting bolt

M10 Ý 1.5

2.8 Ü 0.3

20.3 Ü 2.2

Main pump mounting socket bolt

M20 Ý 2.5

42 Ü 4.5

304 Ü 32.5

Main control valve mounting nut

M12 Ý 1.75

Fuel tank mounting bolt

Engine

12.2 Ü 1.3

88.2 Ü 9.4

M20 Ý 2.5

46 Ü 5.0

333 Ü 36

Hydraulic oil tank mounting bolt

M20 Ý 2.5

46 Ü 5.0

333 Ü 36

Turning joint mounting bolt, nut

M12 Ý 1.75

12.3 Ü 1.3

88.9 Ü 9.4

Swing motor mounting bolt

M20 Ý 2.5

58.4 Ü 6.4

422 Ü 46

Swing bearing upper part mounting bolt

M24 Ý 3.0

97.8 Ü 10

707 Ü 72.3

Swing bearing lower part mounting bolt

M24 Ý 3.0

97.8 Ü 10

707 Ü 72.3

Travel motor mounting bolt

M24 Ý 3.0

100 Ü 10

723 Ü 72.3

Sprocket mounting bolt

M20 Ý 2.5

51 Ü 4.0

369 Ü 28.9

Carrier roller mounting bolt, nut

M16 Ý 2.0

29.7 Ü 4.4

126 Ü 31.8

Track roller mounting bolt

M20 Ý 2.5

57.9 Ü 8.6

419 Ü 62.2

Track tension cylinder mounting bolt

M12 Ý 1.25

15 Ü 0.5

108 Ü 3.6

Track shoe mounting bolt, nut

M22 Ý 1.5

115 Ü 5.0

831 Ü 36

Track guard mounting bolt

M20 Ý 2.5

46 Ü 5.0

333 Ü 36

Counter weight mounting bolt

M36 Ý 3.0

297 Ü 33

2148 Ü 239

Cab mounting bolt

M12 Ý 1.75

12.2 Ü 1.3

88.2 Ü 9.4

Operator's seat mounting bolt

M 8 Ý 1.25

2.5 Ü 0.5

18.1 Ü 3.6

8 9

13 14 15

Hydraulic system

Power train system

18 19

23 24

Under carriage

Others

ö For tightening torque of engine and hydraulic components, see engine maintenance guide and service manual.

6-8

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

3. FUEL, COOLANT AND LUBRICANTS 1) NEW MACHINE New machine used and filled with following lubricants. Specification

Description Engine oil

SAE 15W-40(API CF-4)

Hydraulic oil

ISO VG 46(SAE 10W)

Swing and travel reduction gear

SAE 85W-140(API GL-5)

Grease

Lithium base grease NLGI No. 2

Fuel

ASTM D975-No. 2

Coolant

Mixture of 50% ethylene glycol base antifreeze and 50% water.

SAE API ISO NLGI ASTM

: : : : :

Society of Automotive Engineers American Petroleum Institute International Organization for Standardization National Lubricating Grease Institute American Society of Testing and Material

6-9

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

2) RECOMMENDED OILS Use only oils listed below or equivalent. Do not mix different brand oil. Service point

Kind of fluid

Ambient temperature 。 C (。 F)

Capacity ℓ(U.S. gal)

-20 (-4)

-10 (14)

0 (32)

10 (50)

20 (68)

30 (86)

SAE 30 Engine oil pan

19(5.0) Engine oil

SAE 10W

24(6.3) (TIER II)

SAE 10W-30 SAE 15W-40

7.0(1.8)

Swing drive Gear oil Final drive

Hydraulic tank

Hydraulic oil

SAE 85W-140

11×2 (2.9×2)

ISO VG 32

Tank; 210(55.5)

ISO VG 46 System; 320(84.5)

ISO VG 68

ASTM D975 NO.1 Fuel tank

Diesel fuel

480(126.8) ASTM D975 NO.2

Fitting (Grease nipple)

Grease

Radiator (Reservoir tank)

Mixture of antifreeze and water 50 : 50

SAE API ISO NLGI ASTM

NLGI NO.1

As required

NLGI NO.2

Ethylene glycol base permanent type

50(13.2)

: Society of Automotive Engineers : American Petroleum Institute : International Organization for Standardization : National Lubricating Grease Institute : American Society of Testing and Material

6-10

40 (104)

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

4. MAINTENANCE CHECK LIST 1) DAILY SERVICE BEFORE STARTING Check items

Service

Page

Fuel tank

Check, Refill

6-25

Hydraulic oil level

Check, Add

6-30

Engine oil level

Check, Add

6-18

Coolant level

Check, Add

6-20

Control panel & pilot lamp

Check, Clean

6-39

Water separator

Check, Drain

6-26

Fan belt tension

Check, Adjust

6-24

Service

Page

Drain

6-25

Track tension

Check, Adjust

6-34

Swing bearing

Lubricate

6-32

Check, Add

6-32

Lubricate

6-38

Visual check

2) EVERY 50 HOURS SERVICE Check items Fuel tank

Swing reduction gear oil Lubricate pin and bushing ·Boom cylinder tube end ·Boom foot ·Boom cylinder rod end ·Arm cylinder tube end ·Arm cylinder rod end ·Boom + Arm connecting ·Bucket cylinder tube end ·Bucket cylinder rod end ·Arm + Bucket connecting ·Arm + Link, Bucket control ·Bucket control rod

6-11

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

3) INITIAL 50 HOURS SERVICE Check items

Service

Page

Engine oil

Change

6-18, 19

Engine oil filter

Replace

6-18, 19

Pilot line filter

Replace

6-31

Hydraulic return filter

Replace

6-30

Drain filter cartridge

Replace

6-31

Fuel filter

Replace

6-26

Check, Tight

6-8

Bolts & Nuts ·Sprocket mounting bolts ·Travel motor mounting bolts ·Swing motor mounting bolts ·Swing bearing mounting bolts ·Engine mounting bolts ·Counterweight mounting bolts ·Turning joint locating bolts ·Track shoe mounting bolts and nuts ·Hydraulic pump mounting bolts

Service the above items only for the new machine, and thereafter keep the normal service interval.

4) EVERY 100 HOURS SERVICE Check items

Service

Page

★ Return filter

Replace

6-30

★ Pilot line filter

Replace

6-31

★ Element in hydraulic tank breather

Replace

6-31

★ Drain filter cartridge

Replace

6-31

★ Replace 4 filters for continuous hydraulic breaker operation only.

6-12

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

5) EVERY 250 HOURS SERVICE Service

Page

★ Engine oil

Change

6-18, 19

★ Engine oil filter

Replace

6-18, 19

Battery electrolyte

Check, Add

6-39

Hydraulic oil return filter

Replace

6-30

Drain filter cartridge

Replace

6-31

☆ Swing reduction gear oil

Change

6-32

Check, Add

6-32

Pilot line filter

Replace

6-31

Element in hydraulic tank breather

Replace

6-31

Check, Tight

6-8

Check items

☆ Swing reduction grease(#2206-)

★ If you use high sulfur containing fuel above than 0.5% or use low grade of engine oil reduce change interval. ☆ Change oil and add grease after initial 250 hours of operation.

6) EVERY 500 HOURS SERVICE Check items

Service

Page

Engine oil(TIER II)

Change

6-18, 19

Engine oil filter(TIER II)

Replace

6-18, 19

Radiator and cooler fin

Inspect, Clean

6-23

★Air cleaner element

Check, Clean

6-25

Replace

6-26

Check, Add

6-33

Change

6-33

Fuel filter Travel reduction gear oil ☆Travel reduction gear oil

★ Clean the primary element only after 500 hours operation or when the air cleaner warning lamp blinks. Replace primary element and safety element after 4 times cleanings of primary element. ☆ Change oil after initial 500 hours of operation.

6-13

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

7) EVERY 1000 HOURS SERVICE Check items

Service

Page

Travel motor reduction gear oil

Change

6-33

Swing reduction gear oil

Change

6-32

Swing reduction gear grease(#2206-)

Change

6-32

Grease in swing gear and pinion

Change

6-33

Service

Page

Change

6-29

Check, Clean

6-30

Change

6-20, 21, 22, 23

8) EVERY 2000 HOURS SERVICE Check items Hydraulic tank ★·Oil ·Suction strainer Coolant

★Change oil every 600 hours of continuous hydraulic breaker operation.

6-14

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

9) WHEN REQUIRED Whenever you have trouble in the machine, you must perform the service of related items, system by system. Check items

Service

Page

Drain or Clean

6-25

Drain or Replace

6-26

Replace

6-26

·Engine oil

Change

6-18, 19

·Engine oil filter

Replace

6-18, 19

·Coolant

Add or Change

6-20, 21, 22, 23

·Radiator

Clean or Flush

6-20, 21, 22, 23

Replace

6-25

·Hydraulic oil

Add or Change

6-29

·Return filter

Replace

6-30

·Drain line filter

Replace

6-31

·Pilot line filter

Replace

6-31

·Element of breather

Replace

6-31

Clean

6-30

Check, Adjust

6-34

·Tooth

Replace

6-36

·Side cutter

Replace

6-36

Adjust

6-37

Replace

6-35

Clean, Replace

6-42

Clean

6-43

Fuel system ·Fuel tank ·Water separator ·Fuel filter Engine lubrication system

Engine cooling system

Engine air system ·Air cleaner element Hydraulic system

·Suction strainer Undercarriage ·Track tension Bucket

·Linkage ·Bucket assy Air conditioner and heater ·Fresh filter ·Recirculation filter

6-15

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

5. MAINTENANCE CHART

9 13 22 23 19 2 7

21 16 4 11 20 15 5

26 24 10

6 14 8

18 29076MI05A

Caution 1. Service intervals are based on the hour meter reading. 2. The number of each item shows the lubrication point on the machine. 3. Stop engine while filling oil, and use no open flames. 4. For other details, refer to the service manual.

6-16

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

Service interval

10 Hours or daily

50 Hours or weekly

250 Hours

No.

2000 Hours

As required

Service points No.

Fuel tank

Check, Refill

480(126.8)

Hydraulic oil level

Check, Add

210(55.4)

Engine oil level

Check, Add

19(5.0)

Engine oil level(TIER II)

Check, Add

24(6.3)

Radiator coolant

Check, Add

50(13.2)

Control panel & pilot lamp

Check, Clean

Water separator

Check, Drain

Attachment pins

Check, Add

PGL

Fuel tank strainer and drain

Check, Clean

Check, Adjust

PGL

0.3(0.08)

12 Swing bearing grease

Check, Add

PGL

17 Swing drive gear case

Check, Add

7(1.8)

Change

19(5.0)

Check, Add

11 Engine oil filter

Replace

13 Hydraulic oil return filter

Replace

21 Line filter element

Replace

22 Drain filter cartridge

Replace

23 Air breather element

Replace

Engine oil level(TIER II)

Change

24(6.3)

11 Engine oil filter(TIER II)

Replace

Clean

Check, Clean

Replace

18 Final drive gear case

Check, Add

11(2.9)

17 Swing drive gear case

Change

7(1.8)

18 Final drive gear case

Change

11(2.9)

Check, Adjust

24 Swing gear and pinion

Change

PGL

26 Swing reduction gear grease(#2206-)

Change

PGL

1.8(0.5)

10 Track tension

Engine oil level

Battery(Electrolyte)

14 Air cleaner element 15 Radiator and cooler fin 16 Fuel filter element

1000 Hours

Oil Capacity symbol ℓ(U.S.gal)

500 Hours

Service action

Description

20 Fan belt tension and damage

Hydraulic oil level

Change

210(55.4)

Radiator coolant

Change

50(13.2)

19 Hydraulic oil suction strainer

Check, Clean

25 Air conditioner filters

Check, Clean

※ Oil symbol Please refer to the recommended lubricants for specification. DF : Diesel fuel GO : Gear oil HO : Hydraulic oil C : Coolant PGL : Grease EO : Engine oil 6-17

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

6. SERVICE INSTRUCTION 1) CHECK ENGINE OIL LEVEL Check the oil level with the machine on a flat ground before starting engine. (1) Pull out the dipstick and wipe with a clean cloth. (2) Check the oil level by inserting the dipstick completely into the hole and pulling out again. (3) If oil level is LOW, add oil and then check again. ※ If the oil is contaminated or diluted, change the oil regardless of the regular change interval. ※ Check oil level after engine has been stopped for 15 minutes. Do not operate unless the oil level is in the normal range.

TIER II

29076MI06

2) REPLACEMENT OF ENGINE OIL AND OIL FILTER (1) Warm up the engine. (2) Remove the plug and allow the oil to drain. ·Adaptor size : 1/2~3/8mm ※ A drain pan with a capacity of 25 liters (6.6U.S. gallons) will be adequate. 36076MA06A

(3) Clean around the filter head, remove the filter and clean the gasket surface. ·Wrench size : 90 ~ 95mm(3.5~3.8in)

21076MA06A

6-18

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

(4) Apply a light film of lubricating oil to the gasket sealing surface before installing the filters. ※ Fill the filters with clean lubricating oil.

Oil

18036MI09

(5) Install the filter to the filter head. ※ Mechanical over-tightening may distort the threads or damage the filter element seal. ·Install the filter as specified by the filter manufacturer.

18036MI10

(6) Fill the engine with clean oil to the proper level. ·Quantity : 19ℓ(5U.S.gallons) 16.4ℓ(4.3U.S.gallons TIER II)

Oil

29076MI06A

(7) Operate the engine at low idle and inspect for leaks at the filters and the drain plug. Shut the engine off and check the oil level with the dipstick. Allow 15minutes for oil to drain down before checking.

29076MI06B

6-19

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

3) CHECK COOLANT (1) Check if the level of coolant in reservoir tank is between FULL and LOW. (2) Add the mixture of antifreeze and water after removing the cap of the reservoir tank if coolant is not sufficient.

(3) Be sure to add the coolant by opening the cap of radiator when coolant level is below LOW. (4) Replace gasket of radiator cap when it is damaged. Hot coolant can spray out if radiator cap is removed while engine is hot. Remove the cap after the engine has cooled down.

21076MA07

NOT OK

21076MA08

4) FLUSHING AND REFILLING OF RADIATOR (1) Change coolant Avoid prolonged and repeated skin contact with used antifreeze. Such prolonged repeated contact can cause skin disorders or other bodily injury. Avoid excessive contact-wash thoroughly after contact. Keep out of reach of children. â&#x20AC;ť Protect the environment : Handling and disposal of used antifreeze can be subject to federal, state, and local law regulation. Use authorized waste disposal facilities, including civic amenity sites and garages providing authorized facilities for the receipt of used antifreeze. If in doubt, contact your local authorities for guidance as to proper handling of used antifreeze.

6-20

21076MA09

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

Wait until the temperature is below 50。 C (120。。 F) before removing the coolant system pressure cap. Failure to do so can cause personal injury from heated coolant spray. Drain the cooling system by opening the drain valve on the radiator and removing the plug in the bottom of the water inlet. A drain pan with a capacity of 40 liters(10U.S.gallons) will be adequate in most applications. (2) Flushing of cooling system ① Fill the system with a mixture of sodium carbonate and water(or a commercially available equivalent). ※ Use 0.5kg(1.0pound) of sodium carbonate for every 23 liters(6.0U.S. gallons) of water. ※ Do not install the radiator cap. The engine is to be operated without the cap for this process.

18036MI16

18036MI17

※ During filling, air must be vented from the engine coolant passages. Open the engine venting petcock. The system must be filled slowly to prevent air locks. Wait 2 to 3 minutes to allow air to be vented, then add mixture to bring the level to the top.

18036MI18

② Operate the engine for 5 minutes with the coolant temperature above 80。 C(176。 F) . Shut the engine off, and drain the cooling system.

START

ON OFF 21076MA10

6-21

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

③ Fill the cooling system with clean water. ※ Be sure to vent the engine and aftercooler for complete filling. ※ Do not install the radiator cap or the new coolant filter.

18036MI20

④ Operate the engine for 5 minutes with the coolant temperature above 80。 C(176。 F) . Shut the engine off, and drain the cooling system. ※ If the water being drained is still dirty, the system must be flushed again until the water is clean.

START

ON OFF

(3) Cooling system filling ① Use a mixture of 50 percent water and 50 percent ethylene glycol antifreeze to fill the cooling system. Coolant capacity(engine only) : 9.5ℓ(2.5U.S. gallons) / 9.0ℓ(2.4U.S.gallons, TIER II) ※ Use the correct amount of DCA4 corrosion inhibitor to protect the cooling system.

21076MA10

DCA

18036MI22

② The system has a maximum fill rate of 14 liters(3.5U.S. gallons) / 19ℓ(5.0U.S.gallons, TIER II) per minute. ※ Do not exceed this fill rate. The system must be filled slowly to prevent air locks. During filling, air must be vented from the engine coolant passage. Be sure to open the petcock. Then add mixture to bring the level to the top.

6-22

18036MI23

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

③ Install the pressure cap. Operate the engine until it reaches a temperature 80 。 C(176 。 F), and check for coolant leaks. Check the coolant level again to make sure the system is full of coolant.

NOT OK

21076MA10A

5) CLEAN RADIATOR AND OIL COOLER Check, and if necessary, clean and dry outside of radiator and oil cooler. After working in a dusty place, clean radiator more frequently.

NOT OK

(1) Visually inspect the radiator for clogged radiator fins. (2) Use 550kPa(80psi) air pressure to blow the dirt and debris from the fins. Blow the air in the opposite direction of the fan air flow.

550kPa (80psi) 13036MI01

(3) Visually inspect the radiator for bent or broken fins. ※ If the radiator must be replaced due to bent or broken fins which can cause the engine to overheat, refer to the manufacturer's replacement procedures. (4) Visually inspect the radiator for core and gasket leaks.

13036MI01

6-23

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

6) FAN BELT TENSION (1) Measure the belt deflection at the longest span of the belt. ·Maximum deflection : 9.5 - 12.7mm (3/8 to 1/2inch)

18036MI25

(2) Inspect the drive for damage.

NOT OK 13036MI03

(3) Inspect the drive belt, tension bearing and fan hub.

18036MI27

7) INSPECTION OF COOLING FAN Personal injury can result from a fan blade failure. Never pull or pry on the fan. This can damage the fan blade and cause fan failure. ※ Rotate the crankshaft by using the engine barring gear. ※ A visual inspection of the cooling fan is required daily. Check for cracks, loose rivets, and bent or loose blades. Check the fan to make sure it is securely mounted. Tighten the capscrews if necessary. Replace any fan that is damaged.

6-24

NOT OK

21076MA10B

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

8) CLEANING OF AIR CLEANER (1) Primary element ① Loosen the wing nut and remove the element. ② Clean the inside of the body. ③ Clean the element with pressurized air. ·Remove the dust inside of the element by the pressurized air(Below 3kgf/cm2, 40psi) forward and backward equally. ④ Inspect for cracks or damage of element by putting a light bulb inside of the element. ⑤ Insert element and tighten wing nut. ※ Replace the primary element after 4 times cleanings.

Pressurized air 3kgf/cm2 below

Wing nut

(2) Safety element ※ Replace the safety element only when the primary element is cleaned for the 4 times. ※ Always replace the safety element. Never attempt to reuse the safety element by cleaning the element.

21076MA11

21076MA11A

9) FUEL TANK (1) Fill fuel fully when system the operation to minimize water condensation, and check it with fuel gauge before starting the machine. (2) Drain the water and sediment in the fuel tank by opening the drain cock. ※ Be sure to LOCK the cap of fuel tank. ※ Remove the strainer of the fuel tank and clean it if contaminated. Stop the engine when refueling. All lights and flames shall be kept at a safe distance while refueling.

Fuel gauge

Drain cock 21076MA12

6-25

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

10) WATER SEPARATOR (1) Drain the water and sediment by loosening the drain plug.

Red line

(2) Retighten the drain plug. (3) Check for leakage. ※ Drain the water if it reaches the red line regardless of the service interval. ※ Bleed the air if the air is mingled on the fuel line when draining water.

21076MA13

11) REPLACEMENT OF FUEL FILTER (1) Clean around the filter head, remove the filter and clean the gasket surface. ·Wrench size : 90~95mm(3.5~3.8in) (2) Replace the O-ring. (3) Apply engine oil on the gasket of filter when mounting, and tighten 3/4 to 1 turn more after the gasket touches the filter head.

Cartridge 21076MA13A

(4) Relieve the air after mounting. ※ Check for fuel leakage after the engine starts. If air is in the fuel system, the engine will not start. ※ Start engine after bleeding the air according to the method of bleeding air. FUEL WATER SEPARATOR - Drain the water and sediment from the separator daily. - Shut off the engine. - Use your hand to open the drain valve. - Turn the valve counterclockwise 4 complete turns until the valve drops down 1". - Drain the filter sump of water until clear fuel is visible. ※Do not overtighten the valve. Overtightening can damage the threads. - Push the valve up and turn the valve clockwise to close the drain valve. ※IIf more then 2 ozs is drained, refilling of the filter is required to prevent hard starting. Refer to low pressure lines and fuel filter venting clause 12)-(2).

Open

Close 21076MA13B

6-26

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

12) BLEEDING THE FUEL SYSTEM (1) Controlled venting is provided at the injection pump through the fuel drain manifold. Small amounts of air introduced by changing the filters or injection pump supply line will be vented automatically, if the fuel filter is changed in accordance with the instructions. ※ However, manual bleeding will be required if : ·The fuel filter is not filled prior to installation. ·Injection pump is replaced. ·High pressure fuel lines are replaced.

18036MI33

(2) Venting the low pressure lines and fuel filter ① Open the bleed screw. ·Wrench size : 8mm

18036MI34

② Operate the hand lever until the fuel flowing from the fitting is free of air. Tighten the bleed screw. ·Torque : 0.97kgf·m(7lbf·ft)

18036MI35

(3) Venting at the injection pumps ① Bleed the Lucas CAV pump in this illustration. ·Wrench size : 8mm

18036MI36

6-27

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

② Air/fuel can be pumped from this location with the hand lever on the lift pump if the fuel solenoid valve is energized.

START ON OFF

21076MA35

③ Air can be vented from both pumps through the fuel drain manifold line by operating the starting motor. ※ When using the starting motor to vent the system, do not engage it for more than 30 seconds at a time : wait 2 minutes between engagements. ※ It is necessary to put the engine in the RUN position. Because the engine may start, be sure to follow all the safety precautions. Use the normal engine starting procedure. (4) Venting the high pressure lines The pressure of the fuel in the line is sufficient to penetrate the skin and cause serious bodily harm. ① Loosen the fittings at the injectors, and crank the engine to allow entrapped air to bleed from the lines. Tighten the fittings. ·Wrench size :19mm ② Start the engine and vent one line at a time until the engine runs smoothly.

13) LEAKAGE OF FUEL Be careful and clean the fuel hose, injection pump, fuel filter and other connections as the leakage from these part can cause fire.

ST A R O

30 Seconds 21076MA36

NOT OK

ST A R O

30 Seconds 21076MA37

FIRE !!

29076MI35

6-28

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

14) HYDRAULIC OIL CHECK (1) Stop the engine after retract the arm and bucket cylinders, then lower the boom and set the bucket on the ground at a flat location as in the illustration.

Red line

Level gauge

(2) Check the oil level at the level gauge of hydraulic oil tank. (3) The oil level is normal if between the red lines.

15) FILLING HYDRAULIC OIL

21076MA14

Cap

(1) Stop the engine to the position of level check.

Pushing

(2) Loosen the cap and relieve the pressure in the tank by pushing the top of the air breather. (3) Remove the breather on the top of oil tank and fill the oil to the specified level. · Tightening torque : 1.44±0.3kgf·m (10.4±2.1lbf·ft)

Air breather

(4) Start engine after filling and operate the work equipment several times. (5) Check the oil level at the level check position after engine stops.

29076MI04

16) CHANGE HYDRAULIC OIL (1) Lower the bucket on the ground pulling the arm and bucket cylinder to the maximum. (2) Loosen the cap and relieve the pressure in the tank by pushing the top of the air breather.

Cap Air breather

Cover

O-ring

(3) Remove the cover. · Tightening torque : 6.9±1.4kgf·m (50±10lbf·ft) (4) Prepare a suitable container. (5) To drain the oil loosen the drain plug at the bottom of the oil tank. (6) Fill proper amount of recommended oil. (7) Put the breather in the right position. (8) B leed air hydraulic pump loosen the air breather at top of hydraulic pump assembly. (9) Start engine and run continually. Release the air by full stroke of each control lever. 6-29

Drain plug

29076MI15

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

17) CLEAN SUCTION STRAINER Clean suction strainer as follows paying attention to the cause to be kept during oil filling.

Air breather

Cover

O-ring

(1) Remove the cover. · Tightening torque : 6.9±1.4kgf·m (50±10lbf·ft) (2) Pull out the strainer in the tank.

Strainer

(3) Wash the foreign material on the suction strainer with gasoline or cleaning oil. (4) Replace the suction strainer if it is damaged. (5) Assemble with reverse order of disassembly. Be sure to install a new O-ring and reinsert in the oil tank. ※ Loosen the bolt slowly at the cover can be spring out by the spring when removing it. 29076MI16

18) REPLACEMENT OF RETURN FILTER Replace as follows paying attention to the cause to be kept during the replacement. (1) Remove the cover. · Tightening torque : 6.9±1.4kgf·m (50±10lbf·ft)

Cover O-ring

(2) Remove the spring, by-pass valve, and return filter in the tank.

Spring Bypass valve Element

(3) Replace the element with new one.

29076MI17

6-30

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

19) REPLACEMENT OF ELEMENT IN HYDRAULIC TANK BREATHER (1) Loosen the cap and relieve the pressure in the tank by pushing the top of the air breather.

Cap Nut Cover Element

(2) Loosen the lock nut and remove the cover. (3) Pull out the filter element. (4) Replace the filter element new one. (5) Reassemble by reverse order of disassembly. · Tightening torque : 0.2~0.3kgf·m (1.4~2.1lbf·ft)

29076MI18

20) REPLACE OF DRAIN FILTER CARTRIDGE Clean the dust around filter and replace with new one after removing the cartridge. ※ Tighten about 2/3 turn more after the gasket of cartridge contacts seal side of filter body for mounting. ※ Change cartridge after initial 50 hours of operation. Thereafter, change cartridge every 250 hours.

Hydraulic oil tank

21076MA19

21) REPLACE OF PILOT LINE FILTER (1) Loosen the nut positioned on the filter body. (2) Pull out the filter element and clean filter housing. (3) Install the new element and tighten using specified torque. ※ Change cartridge after initial 50 hours of operation. Thereafter, change cartridge every 250 hours.

6-31

Line filter

21076MA20

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

22) CHECK THE SWING REDUCTION GEAR OIL (1) Pull out the dipstick and clean it. (2) Insert it again. (3) Pull out one more time to check the oil level and fill the oil if the level is not sufficient.

21076MA21

23) CHANGE SWING REDUCTION GEAR OIL (1) Raise the temperature of oil by swinging the machine before replace the oil and park the machine on the flat ground.

Filling port plug

(2) Loosen the plug of the drain port. (3) Drain into a proper container. (4) Wash the drain plug and reinstall it with sealing tape. Fill proper amount of recommended oil. ·Amount of oil : 11ℓ(2.9U.S.gal) 24) LUBRICATE BEARING OF OUTPUT SHAFT IN REDUCTION GEAR

Drain port plug 30576MI22

Air vent port plug

(1) Remove air vent plug. (2) Lubricate NLGI No.2 with grease gun unit comes out new grease from air vent port. ※ Lubricate every 50 hours.

Grease filling nipple

2907A6MI24

25) LUBRICATE SWING BEARING (1) Grease at 3 fitting. ※ Lubricate every 50 hours.

13036MI07

6-32

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

26) SWING GEAR AND PINION (1) Drain old grease ① Remove under cover of lower frame. ② Remove drain cover of lower frame. ③ Remove filler cover of upper frame. ④ Operate full turn(360。) of swing several times.

Filler cover

Filler hole

FRONT

2507A6MA28

(2) Refill new grease ① Install drain cover. ② Fill with new grease. ③ Install filler cover. ·Capacity : 10.4kg(23lb)

FRONT

Top of lower frame Drain cover REAR 2507A6MA29

27) CHECK THE TRAVEL REDUCTION GEAR OIL (1) Operate the machine to the position of drain plug down to the flat ground. (2) Loosen the level plug and check the oil level. If the level is at the hole of the plug, it is normal. Fill the oil if it is not sufficient.

Fil

Oil

lev

ain 29076MI23A

28) CHANGE OF THE TRAVEL REDUCTION GEAR OIL (1) Raise the temperature of the oil by traveling machine first. (2) Stop when the position of the drain plug is down.

Fil

(3) Loosen the level plug and then the drain plug.

l le

(4) Drain the oil to adequate container.

ain

(5) Tighten the drain plug and fill specified amount of oil at filling port. (6) Tighten the level plug and travel slowly to check if there is any leakage of oil.

6-33

29076MI24

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

28) LUBRICATE RCV LEVER Remove the bellows and with a grease gun grease the joint part(A) and sliding parts(B).

21076MA25

29) ADJUSTMENT OF TRACK TENSION ※ It is important to adjust the tension of track properly to extend the lifetime of track and traveling device. ※ The wear of pins and bushings on the undercarriage will vary with the working conditions and soil properties. It is thus necessary to continually inspect the track tension so as to maintain the standard tension on it. (1) Raise the chassis with the boom and arm.

90 ~ 110

Bottom of track frame

Track frame

(2) Measure the distance between bottom of track frame on track center and track of shoe. ※ Remove mud with rotating the track before measuring.

(3) If the tension is tight, drain the grease in the grease nipple and if the tension is loose, charge the grease. Personal injury or death can result from grease under pressure. When loosening the grease nipple, do not loosen more than one turn as there is a danger of a spring coming out of the nipple because of the high pressure inside. ※ When the grease is drained, move the track to the forward and backward slightly. If the track tension is loose even after the grease is charged to the maximum, change the pins and bushings as there are worn seriously.

6-34

Back of shoe

Track shoe 21076MA27

Length(L) 360~390mm

14.2~15.5"

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

30) REPLACEMENT OF BUCKET When knocking the pin in with a hammer, metal particles may fly and cause serious injury, particularly if they get into your eyes. When carrying out this operation, always wear goggles, helmet, gloves, and other protective equipment. ※ When the bucket is removed, place it in a stable condition. ※ When performing joint work, make sure signals to each other and work carefully for safety's sake.

21076MA27

(1) Lower the bucket on the ground as the picture shown in the right.

1 2

3 4

(2) Lock the safety lever to the LOCK position and stop the engine. (3) Remove the stopper bolts(1) and nuts(2), then remove pins(3, 4) and remove the bucket. ※ When removing the pins, place the bucket so that it is in light contact with the ground. ※ If the bucket is lowered strongly to the ground, the resistance will be increased and it will be difficult to remove the pins.

21076MA26

※ After remove the pins, make sure that they do not become contaminated with sand or mud and that the seals of bushing on both sides do not become damaged.

(4) Align the arm with holes(A) and the link with holes(B), then coat with grease and install pins(3, 4) ※ When installing the bucket, the O-rings are easily damaged, so fit the O-rings on the boss of the bucket as shown in the picture. After knocking the pin, move the O-ring down to the regular groove. (5) Install the stopper bolt(1) and nuts(2) for each pin, then grease the pin.

13036MI15

O-ring Nut

Bolt Bucket

Arm boss

Bushing 29076MI36

6-35

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

31) REPLACEMENT OF BUCKET TOOTH (1) Timing of replacement ① Check wearing condition as shown in the illustration and replace tooth tip before adapter starts to wear. ② If excessive use, tooth adapter has worn out, replacement may become impossible.

Tooth adapter Tooth tip

13036MI20

(2) Instructions for replacement ① Pull out pin by striking pin with punch or hammer, avoiding damage to locking washer. ② Remove dust and mud from surface of tooth adapter by using knife. ③ Place locking washer in its proper place, and fit tooth tip to adapter. ④ Insert pin until locking washer is positioned at tooth pin groove. Personal injury can result from bucket falling. Block the bucket before changing tooth tips or side cutters.

6-36

Tooth pin Tooth tip

Tooth adapter Locking washer

13036MI21

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

32) ADJUSTMENT OF BUCKET CLEARANCE (1) Lower the bucket on the ground as the picture shown in the right. (2) Swing to the left and keep the arm boss to be contact to the bucket left. (3) Lock the safety lever to the LOCK position and stop the engine. (4) Measure the clearance(A) between bucket and arm boss. This is the total clearance. (5) Adjusting ① Loosen bolt(2), and remove washer(3), plate(1) and shim(4). ② Remove the shim equivalent value with measuring value. ③ Assemble the parts in the reverse order of removal. ·Tightening torque : 29.6±3.2kgf·m (214.0±23.1lbf·ft) ·Normal clearance : 0.5 ~ 1.0mm (0.02 ~ 0.04in) ※ If the bucket is not adjusted correctly, noise and vibration created during operation, and damaged O-ring, pin and bushing quickly.

6-37

1 2 3 4 Bucket Arm boss

Bushing

29076MI37

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

33) LUBRICATE PIN AND BUSHING (1) Lubricate to each pin of working device Lubricate the grease to the grease nipple according to the lubricating interval. No.

Description

Qty

Lubrication manifold at boom

Boom cylinder pin

Boom and arm connection pin

Arm cylinder pin(Rod side)

Bucket cylinder pin(Head, rod)

Bucket link(Control rod)

Arm and bucket connection pin

Arm and control link connection pin

4 3

※ Shorten lubricating interval when working in the water or dusty place.

21074OP26

(2) Dust seals are mounted on the rotating part of working device to extend the lubricating interval. ※ Mount the lip to be faced outside when replace the dust seal.

21076MA28

※ If it is assembled in wrong direction, it will cause fast wear of pin and bushing, and create noise and vibration during operation. ※ Assemble the seal same direction with picture and use with plastic hammer when replace. Outside

13036MI28

6-38

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

7. ELECTRICAL SYSTEM 1) WIRING, GAUGES Check regularly and repair loose or malfunctioning gauges when found.

13036MI29

2) BATTERY (1) Check and repair ① Check the electrolyte level and fill with distilled water to the prescribed level as necessary. ② Wash the terminal with hot water if it is contaminated, and apply grease to the terminals after washing. Do not stain clothes or skin with electrolyte as it is acid. Be careful not to get the electrolyte in eyes. Wash with clean water and go to the doctor if it enters the eyes. ※ Remove the fire and spark around battery.

Plug

Upper level Lower level 10 ~15mm

13036MI30

(2) Specific gravity of battery Judge the charging rate of battery by the specific gravity. The specific gravity changes by the ambient temperature. Check the charging rate by referring to the chart below. Temperature

20。 C

10。 C

-10。 C

100%

1.26

1.27

1.28

90%

1.24

1.25

1.26

80%

1.22

1.23

1.24

75%

1.21

1.22

1.23

Charging rate

(3) Method of removing the battery cable Remove the cable from the ground connection first( terminal side) and reconnect it last when reassembling.

Specific gravity meter Height of sight Battery

13036MI31

Ground

Battery relay 13036MI32

6-39

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

3) STARTING THE ENGINE WITH A BOOSTER CABLE Keep following order when you are going to start engine using booster cable. (1) Connection of booster cable ※ Use the same capacity of battery for starting. ① Connect the red terminal of booster cable to the battery (+) terminal between exhausted and new battery. ② Connect the black terminal of the booster cable to the battery (-) terminal between exhausted and new battery. ※ Keep firmly all connection, the spark will be caused when connecting finally.

Connection of booster cable Red ③

①

②

Trouble(Exhausted) Normal(New) machine machine Black ④ To chassis of trouble machine

Connection order : ①→②→③→④ 13036MI33

(2) Starting the engine ① Start engine with starting switch. ② If you can not start it by one time, restart the engine after 2 minutes.

START ON OFF

(3) Taking off the booster cable ① Take off the booster cable(black). ② Take off the booster cable(red) connected to the (+) terminal. ③ Run engine with high idle until charging the exhausted battery by alternator, fully. Explosive gas is generated while using the battery or charging it. Keep away flame and be careful not to cause the spark. ※ Charge the battery in the well ventilated place. Place the machine on the earth or concrete. ※ Avoid charging the machine on the steel plate. Do not connect (+) terminal and (-) terminal when connecting booster cable because it will ※ be shorted.

21076MA29

Disconnection of booster cable

Red ③

②

①

Trouble(Exhausted) Normal(New) machine machine Black ④ To chassis of trouble machine

Disconnection order : ④→③→②→① 13036MI33

6-40

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

(4) Welding repair Before start to welding, follow the below procedure. ① Shut off the engine and remove the starting switch. ② Disconnect ground cable from battery by master switch. ③ Before carrying out any electric welding on the machine, the battery cables should be disconnected and the connectors pulled out of the electronic control units(ECM, CPU, cluster etc). ④ Connect the earth(ground) lead of the welding equipment as close to the welding point as possible. ※ Do not weld or flame cut on pipes or tubes that contain flammable fluids. Clean them thoroughly with nonflammable solvent before welding or flame cutting on them. Do not attempt to welding work before carry out the above. If not, it will caused serious damage at electric CAPO system.

6-41

C0L 45 0 EX 11 OB -32 L:R NB DE :21 MORT NO PA

CN CN

-51

-50

CPU Controller

OFF

Master switch Engine controller(ECM) Cluster

I DA UN HY

r Mo

vel

d ee lec Se

Battery

Tra

cel De

CN-56

29076MI40

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

8. AIR CONDITIONER AND HEATER 1) CLEAN AND REPLACE OF FRESH AIR FILTER ※ Always stop the engine before servicing. (1) Move seat and console box to arrow direction using the adjust lever.

Fresh air filter

Adjust lever

21076MA30

(2) Remove the outer filter. ※ When installing a filter, be careful not to change the filter direction.

Outsid Inside 21076MA31

(3) Clean the filter using a pressurized air(Below 2kgf/cm2, 28psi). When using pressurized air, be sure to wear safety glasses. (4) Inspect the filter after cleaning. If it is damaged or badly contaminated, use a new filter.

Inside Outside Pressurized air 2kgf/cm2 below

13036MI34

2) CLEAN AND REPLACE OF RECIRCULATION FILTER ※ Always stop the engine before servicing. (1) Move seat and console box to arrow direction using the adjust lever.

Adjust lever

6-42

Recirculation filter 21076MA32

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

(2) Remove recirculation filter.

21076MA33

(3) Clean the recirculation filter using a pressurized air (Below 2kgf/cm2, 28psi) or washing with water. When using pressurized air, be sure to wear safety glasses. â&#x20AC;ť Dry off after washing with water. (4) Inspect the filter after cleaning. If it is damaged or badly contaminated, use a new filter.

Pressurized air 2kgf/cm2 below

13036MI35

3) PRECAUTIONS FOR USING AIR CONDITIONER (1) When using the air conditioner for a long time, open the window once every one hour. (2) Be careful not to overcool the cab. (3) The cab is properly cooled if the operator feels cool when entering there from outside(About 5ă&#x20AC;&#x201A; C lower than the outside temperature). (4) When cooling, change air occasionally. 4) CHECK DURING SEASON Ask the service center for replenishment of refrigerant or other maintenance service so that the cooling performance is not damaged. 5) CHECK DURING OFF-SEASON Operate the air conditioner 2 or 3 times a month(Each for a few minutes) to avoid loss of oil film in the compressor.

6-43

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

TROUBLESHOOTING GUIDE 1. ENGINE This guide is not intended to cover every conditions, however many of the more common possibilities are listed. Service

Trouble

The engine oil pressure lamp · Add the oil to the specified level. lights ON when engine speed is · Replace the oil filter cartridge. raised after completion of warm · Check oil leakage from the pipe or the joint. up.

· Replace the monitor. Steam is emitted from the top part of the radiator(The pressure valve). Coolant level warning lamp lights ON.

· Supply the coolant and check leakage. · Adjust fan belt tension. · Wash out inside of cooling system. · Clean or repair the radiator fin. · Check the thermostat. · Tighten the radiator cap firmly or replace the packing of it.

· Replace the monitor. The engine does not start when · Add fuel. the starting motor is turned over. · Repair where air is leaking into fuel system.

· Check the injection pump or the nozzle. · Check the valve clearance. · Check engine compression pressure. Exhaust gas is white or blue.

· Adjust to specified oil quantity. · Replace with specified fuel.

Exhaust gas occasionally turns · Clean or replace the air cleaner element. black. · Check the nozzle.

· Check engine compression pressure. · Clean or replace the turbocharger. Combustion noise occasionally · Check the nozzle. changes to breathing sound. Unusual combustion noise or · Check with specified fuel. mechanical noise. · Check over-heating

· Replace the muffler. · Adjust valve clearance.

7-1

Remark

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

2. ELECTRICAL SYSTEM Trouble

Service

Lamp does not glow brightly even · Check for loose terminals and open-circuit wiring. when engine runs at high speed. · Adjust belt tension. Lamp flickers while engine runs. Battery charging lamp does not · Check the alternator. go out even when engine runs at · Check and repair wiring. high speed. Unusual noise is emitted from the · Check the alternator. alternator. Starting motor does not turn when · Check and repair the wiring. starting switch is turned ON. · Charge the battery.

· Check the starting motor. · Check the safety relay. The pinion of the starting motor · Charge the battery. keeps going in and out. · Check the safety relay. Starting motor turns the engine · Charge the battery. sluggishly. · Check the starting motor. The starting motor disengages · Check and repair the wiring. before the engine starts up. · Charge the battery. The engine warming up lamp · Check and repair wiring. does not go ON. · Check the monitor. The engine oil pressure lamp · Check the monitor. does not light up when engine is · Check the caution lamp switch. stationary(When the starting switch is in ON position.) Battery charging lamp does not · Check the monitor. light up when the engine is · Check and repair the wiring. stationary. (When the starting switch is in ON position.)

7-2

Remark

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

3. OTHERS Trouble Track slip out of place. Excessive wear of the sprocket.

Service

· Adjust tension of track.

Bucket either rises slowly or not at · Add oil to specified level. all. Slow speed of travel, swing, boom, arm and bucket.

· Add oil to specified level.

Unusual noise emitted from pump. · Clean the hydraulic tank strainer. Excessive oil temperature rise of hydraulic oil.

· Clean the oil cooler. · Adjust fan belt tension. · Add oil to specified level.

7-3

Remark

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

HYDRAULIC BREAKER AND QUICK CLAMP 1. SELECTING HYDRAULIC BREAKER 1) Become familiar with the manual and select breakers suitable to machine specifications. 2) Make careful selection in consideration of oil quantity, pressure and striking force, to enable satisfied performance. 3) When apply a breaker to the machine, consult your local dealer of Hyundai for further explanation.

8-1

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

2. CIRCUIT CONFIGURATION 1) As for breaker oil pressure line, use extra spool of main control valve. 2) Set proper breaker pressure on load relief valve. 3) The pressure of the ROBEX290LC-7 system is 330kgf/cm2(4700psi).

4) Adjusting oil quantity

Oil quantity according to engine rpm

(1) Use the breaker mode from work mode. Default oil flow quantity is 220lpm at 1900rpm. Use accel dial switch to control the oil flow quantity. (2) If the quantity of hydraulic oil is not controlled properly, it causes short lifecycle of the breaker and the machine by increased breaking force and count.

Engine rpm

Oil flow â&#x201E;&#x201C;/min

Oil flow U.S.gpm

1800

207

54.7

1700

195

51.5

1600

184

48.6

1500

172

45.4

â&#x20AC;ťRelief pressure : 200kgf/cm2

5) The accumulator should be used to the breaker charging and return line. If the accumulator is not used, it will be damage as the input wave is delivered. 6) Do not connect the breaker return line to the main control, but connect to the return line front of the cooler. 7) Do not connect the breaker return line to drain lines, such as of swing motor, travel motor or pump, otherwise they should be damaged. 8) One of spool of the main control valve should be connected to the tank. 9) Select the size of pipe laying considering the back pressure. 10) Shimless tube should be used for the piping. The hose and seal should be used Hyundai genuine parts. 11) Weld the bracket for pipe clamp to prevent damage caused by vibration.

8-2

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

3. MAINTENANCE 1) MAINTENANCE OF HYDRAULIC OIL AND FILTER (1) As machine with an hydraulic breaker provides the hydraulic oil becomes severely contaminated. (2) So, unless frequently maintained, the machine may easily go out of order. (3) Inspect and maintain hydraulic oil and 4 kinds of filter elements in particular, in order to prolong machine life. (4) Replace when the breaker work is used for short time according to the standard of right graph. 2) RELEASE THE PRESSURE IN BREAKER CIRCUIT When breaker operating is finished, stop engine and push pedal or switch for breaker to release pressure in breaker circuit. If pressure still remains, the lifetime of the diaphragm in the accumulator will be shortened.

Service interval Operating Hydraulic rate oil

Attachment

Filter element

Bucket

100%

2,000

250

Breaker

100%

600

100

● Replace following filter same time ·Hydraulic return filter : 1EA ·Pilot line filter : 1EA ·Element in hydraulic tank breather : 1EA ·Drain filter cartridge : 1EA

Filter replace guide for hydraulic breaker 100 Average operating rate of machine (%)

Time to replace filter elements

80 60 40 20

3) Be careful to prevent contamination by dust, sand and etc. If such pollution become mixed into the oil, the pump moving parts will wear abnormally, shorten lifetime and become damaged. 4) When operating breaker, bolts and nuts of main equipment may be loosened by vibration. So, it must be inspected periodically.

unit : hours

0 50

100

150

200 250

Operating hours of machine(Hr)

Oil change guide for hydraulic breaker 100 Average operating rate of machine (%)

80 Time to change oil

60 40 20 0 500

1000

1500

2000

Operating hours of machine(Hr)

8-3

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

4. PRECAUTIONS WHILE OPERATING THE BREAKER 1) DO NOT BREAK ROCK WHILE LOWERING As the breaker is heavy in comparison with bucket, it must be operated slowly. If breaker is rapidly pushed down, working device may be damaged.

Incorrect

13038OA03

2) DO NOT USE BREAKER TO CARRY BROKEN STONE OR ROCK BY SWING OPERATING This may damage the operation device and swing system.

Incorrect

13038OA04

3) OPERATE BREAKER WITH A GAP IN EXCESS OF 100mm(4 inches) FROM THE END OF THE STROKE TIP If breaker is operated with the end tip, the cylinder may be damaged.

Incorrect

13038OA05

4) IF THE HYDRAULIC HOSES VIBRATE EXCESSIVELY If the machine used in this condition continuously this will effect badly on the machine such as loosening bolt, oil leakage, damage of pump pipe and etc.

Incorrect

13038OA06

8-4

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

5) DO NOT CONTINUE TO WORKING OVER ONE MINUTE AT SAME POSITION OF BOOM AND ARM This will increase the temperature of the oil, and cause problem in the accumulator and seals.

Incorrect For one minute

13038OA07

6) DO NOT MOVE MACHINE OR BREAKER WHILE STRIKING Do not move hammer while striking. This will cause damage to the working device and the swing system.

Incorrect

13038OA08

7) DO NOT WORK WHILE SWING STATE Do not work while swing position of superstructure. It cause the band of track shoe, oil leakage of roller.

Prohibitation

Work

Prohibitation 13038OA09

8) TAKE CARE OF CHISEL AND BOOM INTERFACE Make sure of the arm and bucket control lever operation.

Incorrect

13038OA10

8-5

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

5. QUICK CLAMP 1) FIXING BUCKET WITH QUICK CLAMP Quick clamp switch

(1) Before fixing bucket, remove safety pin of the moving hook.

Safety button

(2) Pulling safety button, press the quick clamp switch to unlock position. Then, the moving hook is placed on release position.

Safety pin

(3) Aligning the arm and bucket, insert static hook of quick clamp to the bucket pin. Static hook

(4) Operate RCV lever to bucket-in position. Then, the moving hook is coupled with the bucket link pin. Make sure that the moving hook is completely contacted with bucket link pin.

Moving hook

(5) Press quick clamp switch to lock position. Operate RCV lever to bucket-in position. â&#x20AC;ť Be sure to check connection status between bucket pins and hooks of quick clamp

RCV(RH)

Front

8-6

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

(6) After checking the connection status between bucket pins and hooks of quick clamp, insert safety pin of moving hook to lock position. Safety pin

2) REMOVE BUCKET FROM QUICK CLAMP Removing procedure is reverse of fixing. 3) PRE-CAUTION OF USING QUICK CLAMP. When operating the machine with quick clamp, confirm that the quick clamp switch is lock position and safety pin of moving hook is inserted. Operating the machine with quick clamp switch unlocked and without safety pin of moving hook can cause the bucket to drop off and bring about the accident.

Lock

Serious injury or death can result from this accident. Be careful to operate the machine equipped with quick clamp. The bucket may hit cab, boom and boom cylinders when it reaches vicinity of them. HYUNDAI will not be responsible for any injury or damage in case that safety pin is â&#x20AC;» not installed properly.

8-7

Unlock

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

INDEX

A Accel dial switch After engine start Air breather element Air cleaner filter Air conditioner & heater Air conditioner filter Alternate exit Attachment lowering

Fuel system bleeding Fuel tank Fuse box

3-10 4-4 6-31 6-25 3-17 6-42 0-12 4-25

H Hydraulic breaker Hydraulic oil changing Hydraulic oil filling Hydraulic oil level

Levers & pedals Lifting capacities Lubricant specification

6-39 4-2 4-25 6-37 6-35 2-22 6-35

Maintenance check list Major component Mode selection system Monitor display Monitor panel Mounting and dismounting

6-42 3-1 3-20 4-28 3-24 6-20 6-24 3-26

New machine operation

Oil cooler Operating pattern

6-23 4-28

P Pedals Periodical replacemnet parts Pilot filter Pin & bushing adjustment

6-31

6-18 6-18 4-3 6-40 4-6

3-16 3-14 6-31 6-38

R Radiator flushing Radio RCV lever lubricate Recommended oils Relieving pressure Resistor Return filter

F Fan belt Fuel filter Fuel leakage

4-1

E Engine oil filter Engine oil level Engine starting & stop Engine starting by booster Engine stop

6-11 2-1 4-7 4-11 3-2 1-12

D Drain filter

3-14 2-8 2-30

C Cab air filter Cab device Cassette & radio Changing machine control pattern Cigar lighter Coolant Cooling fan CPU controller

8-1 6-29 6-29 6-29

B Battery Before starting engine Boom lowering Bucket clearance adjustment Bucket replacement Bucket selection guide Bucket tooth replacement

6-27 6-25 3-25

6-24 6-26 6-28

9-1

6-20 3-20 6-34 2-30, 6-10 6-3 3-26 6-30

AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

S Safety hints Safety labels Safety parts Seat Seat belt Service meter Speciation for major component Specification Start switch Storage Suction strainer Swing bearing grease Swing gear & pinion grease Swing reduction gear oil Switch panel Switches

1-1 0-5 6-5 3-24 3-24 3-26 2-26 2-2 3-9 4-26 6-30 6-32 6-33 6-32 3-7 3-9

T Torques-major component Torques-fastener Towing machine Track adjustment Track shoe selection Transportation Travel reduction gear oil Travelling machine Troubleshooting guide

6-8 6-6 4-17 6-34 2-24 5-1 6-33 4-15 7-1

U Undercarriage

2-24

W Warming up operation Warning lamps Water separator Weight Working device operation Working method Working range

4-5 3-3 6-26 2-9 4-14 4-18 2-6

9-2